Fuel Injector Integrally Formed Alignment Structures
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Solution Overview
Problem
The existing alignment pin system for fuel injectors in gas turbine engines is costly and inconvenient, requiring multiple components, inspection, and brazing, which complicates the installation and positioning process.
Innovation Solution
The integration of radially extending alignment structures beneath the mounting flange of the fuel injector, which guide and secure the injector into the engine case, eliminating the need for separate alignment pins and brazing, and featuring a leading and trailing alignment structure with distinct shapes and heights to facilitate proper seating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate alignment pins are brazed into the mounting flange, then alignment and positioning accuracy is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The alignment structures are integrated directly into the fuel injector body as a unified component, eliminating the need for separate alignment pins. The mounting flange and alignment structures form a single integrated assembly that is directly formed during manufacturing, thereby reducing part count and eliminating brazing operations while maintaining precise alignment functionality.
Solution Approach 2:
The alignment function is extracted from the separate alignment pin component and incorporated directly into the fuel injector body structure. This allows the alignment capability to be built-in rather than added through separate components and joining processes.
2Manufacturing precision
If separate alignment pins are used, then positioning guidance is improved, but installation time and labor cost increase
Solution Approach 1:
The alignment structures are combined with the fuel injector body as an integrated component, allowing positioning guidance to be inherent to the injector itself. This eliminates the need for separate alignment pin installation and positioning operations during assembly.
Solution Approach 2:
The fuel injector body provides its own alignment functionality through the integrated alignment structures, eliminating the need for external alignment aids or additional positioning operations during installation.
3Reliability
If multiple alignment pins are brazed, then alignment reliability is improved, but manufacturing cost increases
Solution Approach 1:
Multiple alignment structures are merged into a single integrated component formed with the fuel injector body. This maintains the multi-point alignment functionality for reliability while eliminating the costs associated with multiple separate components, procurement, inspection, and brazing operations.
Solution Approach 2:
The integrated alignment structures eliminate the need for expensive separate alignment pins and brazing materials, providing a more cost-effective solution that achieves the same alignment reliability through integrated design.
Data Source
AI summary
A fuel injector for a gas turbine engine is disclosed wherein the engine has an engine case that includes a reception bore for accommodating the fuel injector, and wherein the fuel injector includes a fuel inlet fitting having an annular mounting flange defining opposed upper and lower end surfaces and a cylindrical body portion which depends axially from the lower end surface of the mounting flange, the inlet fitting having integrally formed alignment structure located beneath the lower end surface of the mounting flange for guiding the fuel injector into an installed position within the reception bore of the engine case.