Integrated Rotor Disk Vanes for Lighter Gas Turbine Assemblies
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Solution Overview
Problem
Gas turbine engine designers face challenges in providing improved performance with reduced weights, particularly in rotor disk bores that become large due to increased centrifugal loading at higher turbine speeds, and in accommodating composite materials like ceramic matrix composites (CMC) that require new rotor architectures.
Innovation Solution
A rotor assembly with integrated vanes and disks formed as a monolithic body, featuring dovetail attachments and a design that reduces fluid leakage paths, allowing for reduced weight and improved cooling, using materials such as ceramics and CMCs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple rotor disks are connected by a large number of bolts, then the connection strength and reliability are improved, but the number of fastening operations and assembly complexity increase
Solution Approach 1:
The patent combines multiple fastening functions into a single integrated fastening structure. The fastening component includes a fastening element that engages with both rotor disks simultaneously, eliminating the need for separate bolts for each connection point. This merging of fastening functions reduces the total number of fastening operations while maintaining the required connection strength and reliability between rotor disks.
2Reliability
If traditional multi-bolt fastening is used, then connection reliability is improved, but the assembly time and manufacturing cost increase
Solution Approach 1:
The fastening system is segmented into modular components that can be assembled in a standardized sequence. The fastening component is divided into a fastening element and a fastening structure, allowing for pre-assembly and quality control of individual modules before final installation. This segmentation enables parallel assembly processes and reduces the overall assembly time while maintaining connection reliability through standardized interfaces.
3Strength
If multiple fastening operations are performed, then the mechanical connection is strengthened, but the manufacturing cost and production complexity increase
Solution Approach 1:
The fastening component is designed with universal applicability across different rotor disk configurations. The fastening element and fastening structure are engineered to accommodate various connection requirements through standardized dimensions and interfaces, allowing the same basic design to serve multiple fastening functions. This multi-functionality reduces the need for custom-designed fasteners for each application, thereby lowering manufacturing costs and simplifying production.
Data Source
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AI summary
A rotor assembly is provided for a gas turbine engine. This rotor assembly includes a first rotor disk (180A), a second rotor disk (180B), a plurality of rotor blades (104) and a plurality of vanes (234). The first rotor disk is configured to rotate about a rotational axis (102). The second rotor disk is configured to rotate about the rotational axis. The rotor blades are arranged circumferentially around the rotational axis. Each of the rotor blades is axially between and mounted to the first rotor disk and the second rotor disk. The vanes are arranged circumferentially around the rotational axis. The vanes include a first vane (234) that is integral with the first rotor disk and projects axially to the second rotor disk.