HPC Rotor Assembly Automation for Precise Press-Fit Stacking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of high pressure compressor (HPC) rotor assemblies in gas turbine engines is a manual process that requires significant time and effort, with tight roundness and squareness tolerances, and lacks reliability and repeatability.
Innovation Solution
An automated assembly system using a robot, hydraulic press, and cooling apparatus to stack and secure rotary components along a stacking axis, with interchangeable grippers and sensors for precise alignment and accelerated cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual stacking process is used, then assembly flexibility is maintained, but assembly time increases and repeatability decreases
Solution Approach 1:
The patent replaces the manual mechanical stacking process with an automated robotic system. The robot uses sensors to detect component positions and automatically stacks rotors and impellers, eliminating human operators and significantly reducing assembly time while improving repeatability.
Solution Approach 2:
The stacking station is designed to automatically position and secure components without continuous human intervention. The system uses sensors to self-adjust and the robotic arm to autonomously complete the stacking sequence, making the assembly process self-sufficient.
2Manufacturing precision
If manual assembly process is used, then process adaptability is maintained, but manufacturing precision decreases
Solution Approach 1:
The patent replaces manual positioning with an automated robotic system equipped with sensors that precisely detect component locations. This enables consistent achievement of tight tolerances (0.002 inches roundness and squareness) through repeatable automated movements rather than variable manual operations.
Solution Approach 2:
The stacking station incorporates sensors that continuously monitor component positions and provide feedback to the robotic system. This feedback loop enables real-time adjustment to maintain precise tolerances throughout the assembly process, ensuring consistent quality.
3Reliability
If manual stacking is used, then operational simplicity is maintained, but assembly reliability decreases
Solution Approach 1:
The patent replaces unreliable manual assembly with an automated robotic system that performs consistent, repeatable operations. The robot's programmed movements and sensor feedback ensure every assembly step is performed with the same precision and reliability, eliminating variability introduced by manual operations.
Solution Approach 2:
The automated system performs self-inspection through integrated sensors that verify component positioning and assembly quality without requiring manual inspection. This self-verification capability ensures consistent reliability while the system manages its own complexity through automated control.
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 system improves assembly process repeatability and accuracy while reducing man-hours, ensuring high precision and efficiency in assembling HPC rotor assemblies.
Implementation Method 1
a press system selectably movable between a retracted position spaced apart from the stacking axis and a press position at the stacking axis. The press system is configured to exert a downward force on the two or more rotary components at the stacking station
Implementation Method 2
a cooling apparatus is operably connected to the press system to accelerate cooling of a rotary component of the two or more rotary components. the cooling apparatus is configured to direct a flow of cooling air toward the rotary component
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An automated assembly system for two or more rotary components of a gas turbine engine includes a stacking station (26) at which the two or more rotary components are stacked along a stacking axis (14) and a press system selectably movable between a retracted position spaced apart from the stacking axis (14) and a press position at the stacking axis (14). The press system is configured to exert a downward force on the two or more rotary components at the stacking station (26) to engage a first rotary component of the two or more rotary components to a second rotary component of the two or more rotary components. A robot (30) is configured to sequentially stack the two or more rotary components along the stacking axis (14).