Hybrid Diffuser Case Weight Reduction via Segmentation
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Solution Overview
Problem
Conventional diffuser cases in gas turbine engines are heavy, which poses a challenge in achieving a balance between structural integrity and weight reduction while maintaining effective airflow and combustion efficiency.
Innovation Solution
A hybrid diffuser case design featuring an outer and inner diffuser case wall, struts, compressor case interface, and bearing support, which reduces weight by approximately 15% compared to conventional designs while maintaining structural integrity through strategic placement and use of stiffeners, facilitating improved airflow and combustion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a conventional diffuser case design is used, then structural integrity is maintained, but weight is excessive
Solution Approach 1:
The diffuser case is divided into multiple segments including an outer case, inner case, and multiple struts. This segmentation allows each component to be optimized independently for weight while maintaining the overall structural integrity through the coordinated arrangement of segments.
Solution Approach 2:
The patent employs composite construction combining different materials and structural configurations in the outer case, inner case, and struts. This composite approach enables weight reduction by selecting materials and configurations that provide sufficient structural strength with reduced mass compared to conventional homogeneous designs.
2Use of energy by moving object
If the diffuser case weight is reduced, then fuel efficiency improves, but structural integrity may be compromised
Solution Approach 1:
The diffuser case design incorporates dynamic considerations in the strut configuration and case geometry to maintain structural integrity under varying operational loads while minimizing weight. The structure is designed to adapt to different stress conditions without requiring excessive material.
Solution Approach 2:
The patent optimizes various geometric parameters of the outer case, inner case, and struts to achieve the lightest possible weight while maintaining required structural strength. Parameters such as wall thickness, strut dimensions, and case geometry are carefully selected to balance weight reduction with structural reliability.
3Ease of manufacture
If a lighter diffuser case is designed, then manufacturing cost decreases, but manufacturing precision requirements increase
Solution Approach 1:
By segmenting the diffuser case into modular components (outer case, inner case, struts), the design enables independent manufacturing and assembly of each segment. This modular approach reduces overall manufacturing complexity and cost while allowing for standardized precision requirements on each component.
Solution Approach 2:
The struts serve multiple functions including structural support, positioning of the inner case, and integration with the outer case. This multi-functionality reduces the need for additional specialized components, simplifying manufacturing while maintaining precise geometric relationships through the versatile strut design.
Data Source
AI summary
A hybrid diffuser case for a gas turbine engine includes an outer diffuser case wall that extends downstream from an annular outer pre-diffuser case shroud. An inner diffuser case wall extends downstream from an annular inner pre-diffuser case shroud. A multiple of struts extend between the annular outer pre-diffuser case shroud and the annular inner pre-diffuser case shroud.