Integrally Formed Rotor Disk Bore Basket
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Solution Overview
Problem
Existing gas turbine engine bore baskets are time-consuming and expensive to assemble due to the need for tight tolerances and differential thermal expansion management, leading to potential wear points and reduced lifespan.
Innovation Solution
An integrally formed rotor bore and bore basket unitary structure, where the inner and outer radial panels are welded together with the rotor bore, eliminating the need for separate assembly and allowing for uniform thermal expansion, reducing wear points and improving sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bore baskets are formed from a plurality of separate elements that are assembled together, then the bore basket can be manufactured and assembled in modular sections, but the assembly process becomes time-consuming and expensive due to tight tolerance requirements and differential thermal expansion management
Solution Approach 1:
The patent merges multiple separate bore basket elements into a single integrally formed unitary structure. This eliminates the need for assembly of multiple elements, thereby reducing assembly time and costs while avoiding the complications of tight tolerance requirements and differential thermal expansion between separate elements.
Solution Approach 2:
The integrally formed bore basket is designed with internal segmentation through radially spaced apart tubes that define annular passages. This allows the single structure to perform multiple functions (heat shielding, flow guidance, thermal expansion accommodation) without requiring separate assembled elements.
2Stability of the object's composition
If separate bore basket elements are mechanically connected to allow for differential thermal expansion, then thermal expansion is accommodated, but wear points are created that limit the life of the bore basket
Solution Approach 1:
By combining all bore basket elements into a single integrally formed structure, the patent eliminates mechanical connections between separate elements. This removes wear points caused by relative movement and mechanical fastening, thereby extending bore basket lifespan while maintaining the ability to accommodate thermal expansion through the integrated design.
3Adaptability or versatility
If separate bore basket elements are assembled with mechanical features (anti-rotation keys, snaps), then the elements can be connected while allowing thermal expansion, but the mechanical features create wear points and increase assembly complexity
Solution Approach 1:
The patent eliminates the need for separate mechanical connection features by integrating all bore basket elements into a single piece. This simplifies the device structure, removes assembly complexity, and eliminates wear points associated with anti-rotation keys, snaps, and other mechanical fastening features.
4Manufacturing precision
If separate bore basket elements are assembled to tight tolerances, then proper sealing and alignment are achieved, but the assembly process becomes expensive and time-consuming
Solution Approach 1:
By forming the entire bore basket as a single integrally formed structure, the patent eliminates assembly operations entirely. This removes the need for tight tolerance assembly, thereby reducing manufacturing costs and time while maintaining or improving sealing through the continuous structure.
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 solution simplifies the assembly process, reduces wear, and enhances sealing by eliminating mechanical joints that can cause wear and foreign object damage, while facilitating uniform thermal expansion and tip clearance control across different rotor bore materials and configurations.
Implementation Method 1
the inner radial panel and the outer radial panel may be welded to one another
Implementation Method 2
the bore basket and the rotor bore may be welded to one another
Implementation Method 3
High temperature air in communication with a rotor bore can cause the rotor bore to experience thermal expansion
Data Source
Figure 1
Figure 2
Figure 2A~3
AI summary
A rotor assembly is provided that includes a rotor disk (62) having a bore and a bore basket (72). The bore basket (72) extends axially between a first and second axial ends. The bore basket (72) includes an engagement panel (82), and cylindrical inner and outer radial panels (74, 76). The inner and outer radial panels (74, 76) extend substantially between the first and second axial ends. The inner radial panel (74) is disposed radially inside of and separated from the outer radial panel (76), defining an annular passage (84) disposed there between. The bore basket (72) includes a plurality of inlet apertures (86) in fluid communication with the annular passage (84) at a first axial position (88), and a plurality of exit apertures (90) in fluid communication with the annular passage (84) at a second axial position (92). The second axial end of the bore basket (72) is attached to an inner radial hub (64) of the rotor disk (62), and the disk bore and bore basket (72) are a unitary structure.