Integrated Fan Case Design for Gas Turbine Weight Reduction
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Solution Overview
Problem
The existing gas turbine engine designs incur significant weight and cost due to multiple attachment interfaces between components, which need to be reduced without compromising structural integrity.
Innovation Solution
An integrated single-piece fan case structure that combines the nacelle inlet and fan containment case, eliminating traditional attachment joints and utilizing materials like Kevlar and composite layers for weight savings and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If multiple attachment interfaces are used between components, then structural integrity is maintained, but weight and cost increase significantly
Solution Approach 1:
The patent combines the nacelle inlet and fan containment case into a single integrated component, eliminating the attachment interface between these two parts. This merging removes the weight and cost of bolts, washers, and attachment structures while maintaining the structural integrity of both components through their unified design.
Solution Approach 2:
The integrated inlet structure serves multiple functions simultaneously: it acts as both the nacelle inlet and the fan containment case, while also providing structural support and defining the engine airflow path. This multi-functionality reduces the number of separate components and attachment interfaces needed.
2Ease of manufacture
If multiple attachment interfaces with bolts and washers are used, then component assembly is secure, but manufacturing cost increases
Solution Approach 1:
By integrating the nacelle inlet and fan containment case into one component, the patent eliminates the need for multiple bolts, washers, and attachment structures. This reduces manufacturing cost by removing these fastening elements while maintaining assembly security through the unified structural design.
3Device complexity
If traditional attachment joints are used, then component connection is reliable, but device complexity increases
Solution Approach 1:
The integration of the nacelle inlet and fan containment case into a single component eliminates the attachment joint between them, reducing device complexity by removing this interface. Connection reliability is maintained through the continuous structural design of the integrated component.
Data Source
Figure 1
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AI summary
A fan section (14) of a gas turbine engine (10) includes nacelle inlet (32) and a fan containment case (34) that are integrally formed together as a single-piece component. In one example, the single-piece structure includes a fore end portion (42) that forms the nacelle inlet (32) and an aft portion (44) that forms the fan containment case (34). The single-piece structure has a radially outer circumferential surface (46) and a radially inner circumferential surface (48) at the nacelle inlet and fan containment case. The radially outer and radially inner circumferential surfaces (46,48) provide continuous uninterrupted surfaces from the fore end portion (42) to the aft end portion (44).