Modular Fuel Manifold for Gas Turbine Augmentor
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Solution Overview
Problem
The existing all brazed fuel manifold systems in gas turbine engines are expensive due to gold-nickel braze and complicate maintainability as damage to any single circuit requires removal of the entire manifold.
Innovation Solution
A modular fuel manifold system with multiple brackets and rings, where each fuel manifold is clamped within a support ring, allowing for individual maintenance and assembly, using an all-welded tubing arrangement that is less expensive and easier to fabricate, with brackets providing a flexible design to accommodate thermal motion and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an all brazed fuel manifold system is used, then the structure is unitary and effective, but the cost increases due to gold-nickel braze and maintainability deteriorates as damage requires removal of the entire manifold
Solution Approach 1:
The fuel manifold system is divided into multiple modular zones (first fuel manifold and second fuel manifold) that can be independently removed and replaced. Each zone is secured to the support ring through separate brackets, allowing selective maintenance of individual segments without removing the entire manifold system.
2Reliability
If an all brazed fuel manifold system is used, then the structure is unitary and effective, but the cost increases due to gold-nickel braze
Solution Approach 1:
The manifold is segmented into modular zones that can be manufactured separately using cost-effective welding techniques rather than expensive gold-nickel braze. The modules are then assembled using mechanical brackets and fasteners, reducing overall manufacturing costs while maintaining structural integrity.
Solution Approach 2:
The patent employs conventional welding and mechanical fastening methods instead of expensive brazing materials. The modular design allows individual zones to be replaced as needed, reducing the need for costly gold-nickel braze while maintaining effective fuel distribution.
3Device complexity
If a unitary manifold structure is used, then the system is simple, but maintainability worsens as any damage requires removal of the entire manifold
Solution Approach 1:
The fuel manifold is divided into multiple independent modular zones that can be selectively removed and replaced. Each zone is secured through separate brackets to the support ring, enabling maintenance personnel to access and replace only the damaged zone rather than the entire manifold system.
Solution Approach 2:
The manifold system transitions from a static unitary structure to a dynamic modular configuration where individual zones can be independently installed and removed. The brackets and fasteners enable flexible assembly and disassembly of specific zones while maintaining the overall structural integrity of the support ring.
Data Source
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AI summary
A fuel manifold system (64) for a gas turbine engine includes a first and second fuel manifold (84, 86, 88), the first fuel manifold (84, 86, 88) at least partially nestable within the second manifold (84, 86, 88). A method of assembling a fuel manifold system (64) for a gas turbine engine includes nesting a first fuel manifold (84, 86, 88) at least partially within a second fuel manifold (84, 86, 88).