Integrator Spring Assemblies for Gas Turbine Bypass Valves

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Solution Overview

Problem

Existing spring assemblies in gas turbine engine bypass valves are prone to premature wear and fracturing due to twisting, leading to degraded performance and malfunctioning.

Innovation Solution

The use of additive manufacturing techniques, such as direct metal laser fusion (DMLF) or electron beam melting (EBM), to create integrator spring assemblies with variable pitch and cross-sectional area, eliminating the need for welding or brazing and allowing for multi-material, multi-geometry designs that prevent twisting and reduce stress concentrations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional manufacturing methods (welding or brazing) are used to assemble spring portions, then assembly is simplified, but stress concentrations and premature fracturing occur

Engineering Contradiction:

Improveassembly simplicityVSAvoidstress concentration resistance

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The spring portion, first end portion, and second end portion are formed as a single integral unit using additive manufacturing, eliminating the need for welding or brazing operations while removing stress concentration points at joint interfaces

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Traditional mechanical assembly methods (welding/brazing) are replaced with additive manufacturing technology, substituting a process that creates stress concentrations with a process that creates an integral, stress-free structure

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If constant pitch and cross-sectional area springs are used, then manufacturing is easier, but force-deflection characteristics are not optimized for high-stress environments

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidperformance in high-stress environments

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The spring features variable pitch and variable cross-sectional area along its length, allowing different sections to have optimized properties for their specific functional requirements, improving force-deflection characteristics while maintaining manufacturability through additive processes

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The spring geometry parameters (pitch and cross-sectional area) are varied along the spring length to optimize performance characteristics for high-stress environments, rather than using uniform constant parameters throughout

Inventive Principle:

Principle #35Parameter changes

3Reliability

If anti-rotation features are added to prevent twisting, then spring assembly stability improves, but device complexity increases

Engineering Contradiction:

Improvetwisting preventionVSAvoidspring assembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Anti-rotation features are integrated directly into the spring structure as a single integral component formed by additive manufacturing, eliminating the need for separate anti-rotation devices or features and reducing overall assembly complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spring is formed from a single material continuum without joints or interfaces, creating an inherently stable structure that resists twisting without requiring additional complex anti-rotation mechanisms

Inventive Principle:

Principle #40Composite materials

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

The solution enhances the durability and performance of spring assemblies by minimizing premature wear and fracturing, enabling the production of springs with optimized force-deflection characteristics and extended life, suitable for high-stress environments like gas turbine engines.

Implementation Method 1

direct metal laser fusion (DMLF)

Methodology Applied

Scientific EffectLaser heating and melting: Laser

Implementation Method 2

electron beam melting (EBM)

Methodology Applied

Scientific EffectElectron beam heating and melting: Electron Beam

Implementation Method 3

spring portion disposed between the first and second end portions

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9562616B2Spring assemblies for use in gas turbine engines and methods for their manufacture

Publication Date: 2017.02.07 HONEYWELL INTERNATIONAL INC

AI summary

In accordance with an exemplary embodiment, a method for manufacturing a bypass valve of a turbine engine control system is described. The bypass valve includes a proportional valve and an integrator valve and the integrator valve includes an integrator spring assembly. The method includes forming the integrator spring assembly using an additive manufacturing technique. The integrator spring assembly comprises first and second end portions with a spring portion disposed between the first and second end portions. The first and second end portions and the spring portion are formed as an integral unit without welding or brazing using the additive manufacturing technique. The method further includes assembling the integrator spring assembly, the integrator valve, and the proportional valve into a complete bypass valve assembly.