Gas Turbine Frame Alignment Tool Using Laser Projection
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Solution Overview
Problem
Improper alignment between the forward and aft frames in gas turbine engines can lead to operational issues and premature deterioration, necessitating accurate angular misalignment measurement during assembly.
Innovation Solution
An alignment tool comprising a projection tool and a display tool, where the projection tool projects a marker onto the display tool to gauge the angular misalignment between the frames, utilizing a laser alignment system and adjustable components to ensure precise alignment within predetermined tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If off-the-shelf alignment tools are used, then alignment measurement capability is provided, but cost and complexity increase
Solution Approach 1:
The alignment tool is divided into separate modular components: a projection tool that emits laser markers and a display tool that receives and displays them. These modules can be independently manufactured, calibrated, and assembled, reducing overall system complexity while maintaining measurement precision for angular misalignment between engine frames.
Solution Approach 2:
The alignment tool is designed to measure angular misalignment across multiple engine frame configurations and orientations. The projection and display tools can be positioned at various locations around the engine assembly, making the system universally applicable to different engine types and assembly scenarios without requiring specialized equipment for each case.
2Measurement precision
If traditional alignment methods are used, then alignment capability is provided, but time consumption and efficiency decrease
Solution Approach 1:
Traditional mechanical alignment methods using physical gauges, levels, and manual measurement devices are replaced with an optical laser-based system. The projection tool emits laser markers that are directly visible on the display tool, eliminating the need for complex mechanical measurement chains and reducing measurement time while maintaining or improving precision.
Solution Approach 2:
The projection tool creates optical copies (laser markers) of reference positions that are projected onto the display tool. This optical copying mechanism allows for instant visualization of alignment status without physical contact or complex mechanical intermediaries, significantly reducing measurement time compared to traditional methods.
3Ease of manufacture
If custom alignment tools are developed, then cost is reduced, but manufacturing complexity increases
Solution Approach 1:
By segmenting the alignment tool into standardizable modules (projection tool, display tool, mounting interfaces), each component can be manufactured using conventional processes and assembled through standardized interfaces. This modular approach reduces overall manufacturing complexity compared to developing a completely custom integrated system, while allowing for cost-effective production of individual components.
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
The alignment tool effectively measures and adjusts the angular misalignment between the forward and aft frames, ensuring proper engine assembly and reducing the risk of operational issues and premature deterioration, while being more efficient and cost-effective than off-the-shelf solutions.
Implementation Method 1
The projection tool may include a laser alignment tool. The laser alignment tool may be configured to project a visual marker onto the display tool.
Data Source
AI summary
Devices, systems, and methods for alignment of gas turbine engine components including frame components.