Integrated Valve-Actuator Housing for Lighter Gas Turbine Air Control
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Solution Overview
Problem
Existing gas turbine engines face challenges with the weight and manufacturing complexity of fueldraulic valve assemblies due to their two-part construction, which requires separate high-temperature valve housings and lower-temperature actuator housings, leading to increased weight and lengthy manufacturing processes.
Innovation Solution
An additively manufactured single integral housing body for the fueldraulic valve assembly, constructed from titanium or titanium alloys, integrates the valve and actuator housing with a translation shaft, reducing weight and manufacturing complexity by eliminating the need for separate components and incorporating integral plumbing lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a two-part construction with separate valve housing and actuator housing is used, then the assembly can accommodate different temperature requirements for each housing, but the weight and manufacturing complexity increase
Solution Approach 1:
The patent combines the valve housing and actuator housing into a single integrated housing structure. The valve section and actuator section are formed as one piece through additive manufacturing, eliminating the need for separate housings and reducing assembly complexity while maintaining the ability to accommodate different temperature zones within the unified structure.
Solution Approach 2:
The integrated housing employs different materials or material properties in different regions to accommodate varying temperature requirements. The valve portion exposed to high-temperature engine air uses heat-resistant materials, while the actuator portion operates in lower-temperature zones, achieving local optimization within a unified structure.
2Temperature
If a two-part construction with separate valve housing and actuator housing is used, then the assembly can accommodate different temperature requirements for each housing, but the weight increases
Solution Approach 1:
The integration of valve and actuator housings into a single structure eliminates redundant material and overlapping components. The unified design removes the weight penalty associated with separate housings, fasteners, and sealing interfaces, while the strategic use of materials in different regions maintains temperature resistance where needed.
Solution Approach 2:
The patent utilizes different materials for different portions of the integrated housing. The valve housing portion uses high-temperature resistant materials, while the actuator housing portion uses lighter materials suitable for lower-temperature environments, optimizing the overall weight while maintaining necessary thermal properties.
3Temperature
If traditional manufacturing processes are used for separate housings, then each housing can be manufactured with appropriate materials, but the manufacturing time and cost increase
Solution Approach 1:
The integrated housing is manufactured as a single component using additive manufacturing technology, eliminating the need for separate manufacturing processes, assembly operations, and quality checks for multiple parts. This single-step manufacturing approach significantly reduces production time and cost while maintaining the ability to incorporate different materials for temperature resistance.
Solution Approach 2:
The patent employs additive manufacturing parameters and material selection strategies that enable the production of functionally graded structures with different material properties in different regions. This allows the housing to achieve high-temperature resistance in critical areas while maintaining manufacturing efficiency through a single production process.
Data Source
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AI summary
An engine air valve assembly (100) for a gas turbine engine includes a butterfly valve having a translation shaft and a fueldraulic actuator including a piston. The piston is mechanically linked to the translation shaft by an axial to rotational conversion linkage. A regulating valve housing contains the butterfly valve and the fueldraulic actuator. The regulating valve housing includes an actuator housing portion (120) and a valve housing portion(110) joined via a joint section (130). The regulating valve housing is a single integral piece.