Millable Balance Ring for Gas Turbine Circumferential Imbalance
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Solution Overview
Problem
Circumferential imbalance in rotating components of gas turbine engines leads to wear and reduced lifetime due to manufacturing variances and uneven weight distribution, making standard balance rings ineffective in achieving full balance.
Innovation Solution
A balance ring with a ring-shaped body, anti-rotation tab, and millable balancing features that can be customized to counteract overweight regions by milling counterweights to specific profiles, ensuring static positioning and balanced rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard balance rings are used, then manufacturing is simplified, but circumferential balance precision deteriorates due to manufacturing variances and uneven weight distribution
Solution Approach 1:
The balance ring is provided with millable balancing features (counterweights) in advance, which are then machined to specific profiles to counteract detected overweight regions. This preliminary preparation allows the balance ring to be customized for each rotating component, achieving precise circumferential balance while maintaining a standardized base design that simplifies manufacturing.
Solution Approach 2:
The balancing features are designed with variable parameters (shape, size, position, material density) that can be adjusted through milling operations. By changing these parameters based on measured weight distributions, the balance ring can be precisely tailored to counteract specific imbalance conditions, resolving the contradiction between standardization and precision.
2Manufacturing precision
If balance rings are customized for each rotating component, then circumferential balance precision is improved, but device complexity increases
Solution Approach 1:
The balance ring is segmented into a standardized base structure and customizable balancing features. This segmentation allows the majority of the balance ring to remain standard (simplifying manufacturing and inventory), while only specific features are customized through milling to match the unique weight distribution of each rotating component, reducing overall complexity.
Solution Approach 2:
The balance ring design incorporates universal elements (ring-shaped body, anti-rotation tab, opening) that can be applied across different rotating components, while the balancing features provide component-specific customization. This multi-functionality allows a single balance ring design to serve multiple purposes across different engine configurations without requiring entirely custom designs for each application.
3Manufacturing precision
If milling operations are performed on balancing features, then balance precision is improved, but manufacturing time increases
Solution Approach 1:
The balancing features are pre-formed with millable material in a standardized configuration, allowing rapid customization through controlled milling operations. This preliminary preparation enables the majority of the balance ring to be manufactured using efficient standardized processes, while only specific features require additional milling time to achieve precise balance, minimizing overall manufacturing time loss.
4Measurement precision
If anti-rotation tabs are circumferentially offset, then static positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The anti-rotation tab is deliberately positioned at a circumferential offset (e.g., 180°) from the opening, creating an asymmetric configuration. This asymmetry provides a unique mechanical key that prevents rotation and ensures accurate static positioning of the balance ring on the rotating component. The offset position serves as a reference point that simplifies alignment and positioning accuracy without requiring complex positioning mechanisms.
Data Source
AI summary
A balance ring for a gas turbine engine has a ring shaped body with a first radial thickness, an anti-rotation tab extending outward from the body and at least one millable balancing feature connected to the body.