Fuel Plenum Installation Insert for Micro-Mixer Combustors
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Solution Overview
Problem
Current methods for installing fuel tubes in micro-mixer combustors require precise machining and tight tolerances, leading to increased manufacturing costs, stress on components, and inefficient operation due to the need for precise alignment and brazing of multiple fuel tubes to assembly plates.
Innovation Solution
A fuel plenum design with relaxed tolerances that includes a first and second assembly plate with apertures, where a fuel tube extends through both plates, and an installation insert is positioned between the tube and the plates, allowing for brazing of the insert to the tube and plates, which can accommodate misalignments and reduce manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise machining and tight tolerances are used for fuel tube installation, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent introduces an installation insert as an intermediary component between the fuel tube and the assembly plate. This insert includes a tapered portion that fits into a corresponding tapered aperture in the assembly plate, and a cylindrical portion that receives the fuel tube. The intermediary insert absorbs misalignment tolerances and simplifies the assembly process by providing a guided insertion path, eliminating the need for precise direct alignment between the fuel tube and assembly plate aperture.
Solution Approach 2:
The installation insert is divided into distinct functional segments: a tapered portion for alignment and engagement with the assembly plate, and a cylindrical portion for receiving and guiding the fuel tube. This segmentation allows each portion to perform its specific function optimally, with the tapered portion handling alignment tolerance compensation and the cylindrical portion ensuring proper fuel tube positioning.
2Reliability
If multiple fuel tubes are brazed to a single assembly plate, then fuel tube connection reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The installation insert serves as a mediator that facilitates reliable brazing of multiple fuel tubes to a single assembly plate. The insert's tapered portion provides a stable mounting surface on the assembly plate, while the cylindrical portion provides consistent positioning for each fuel tube. This intermediary structure ensures that all fuel tubes are properly aligned and positioned relative to the assembly plate during brazing, improving joint reliability while reducing the precision requirements for direct tube-to-plate alignment.
3Strength
If tight tolerances are maintained for fuel tube installation, then component strength is improved, but ease of manufacture deteriorates
Solution Approach 1:
The installation insert acts as a buffer that maintains strong brazed joints while significantly easing the manufacturing process. The insert's precise tapered portion ensures strong engagement with the assembly plate, while its cylindrical portion provides generous tolerance for fuel tube insertion. This allows standard fuel tubes with normal tolerances to be easily installed and brazed to the insert, which in turn is brazed to the assembly plate, resulting in strong joints without the need for tight tolerances on the fuel tubes themselves.
4Manufacturing precision
If precise alignment is required for fuel tube brazing, then brazed joint quality is improved, but productivity decreases
Solution Approach 1:
The installation insert dramatically improves installation productivity by providing a guided insertion path through its tapered and cylindrical portions. The tapered portion guides the insert into the assembly plate aperture, and the cylindrical portion guides the fuel tube into proper alignment with the insert. This self-aligning mechanism eliminates the need for time-consuming manual alignment adjustments, allowing rapid assembly while maintaining high brazing quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables fast and efficient fuel tube installation with relaxed tolerances, improving the reliability and longevity of the brazed joint by allowing for some misalignment and reducing manufacturing costs through simpler assembly processes.
Implementation Method 1
The installation inserts may be brazed to the fuel tubes and/or the assembly plates
Data Source
AI summary
The present application provides a fuel plenum for a micro-mixer combustor. The fuel plenum may include a first assembly plate with a first assembly plate aperture, a second assembly plate with a second assembly plate aperture, a fuel tube extending through the first assembly plate aperture of the first assembly plate and the second assembly plate aperture of the second assembly plate, and an installation insert positioned between the fuel tube and the first assembly plate aperture.