Modular Turbomachine Blade Assembly for Thermal Stress Reduction
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Solution Overview
Problem
Existing turbomachine blade designs face challenges with thermal stress concentrations and local material failures due to integral construction, which limits their operational efficiency and requires extensive reconditioning, and they lack flexibility in adapting to different operating regimes without requiring multiple, specifically designed blades.
Innovation Solution
A modular blade assembly with interchangeable modules, including a decoupled inner platform and outer shell, allowing for thermo-mechanical decoupling and the use of various materials and cooling configurations, with an optional intermediate shell for thermal protection and interference fits for secure assembly, enabling adaptation to different operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an integral blade construction is used, then manufacturing simplicity is maintained, but thermal stress concentrations and local material failures occur
Solution Approach 1:
The blade is divided into multiple separable modules including a root module, airfoil module, and tip module that can be independently manufactured and assembled. This segmentation allows each module to be optimized for its specific thermal and mechanical conditions, reducing stress concentrations at module interfaces while maintaining manufacturing simplicity through standardized connection mechanisms.
2Device complexity
If a single blade design is used, then production complexity is reduced, but adaptability to different operating regimes is limited
Solution Approach 1:
The modular blade design employs universal connection interfaces and standardized modules that can be configured in different combinations to suit various operating conditions. The root module serves as a universal base that can accommodate different airfoil and tip module configurations, allowing a single production line to manufacture multiple blade variants for different operating regimes without requiring completely separate tooling.
3Duration of action of moving object
If extensive reconditioning is performed on integral blades, then component lifetime is extended, but operational efficiency is reduced
Solution Approach 1:
Instead of reconditioning the entire integral blade, the modular design allows only the damaged module to be replaced while recovering and reusing the undamaged modules. This approach extends component lifetime by enabling partial replacement rather than complete reconditioning, significantly reducing maintenance time and restoring operational efficiency much faster than traditional reconditioning methods.
4Adaptability or versatility
If modular construction with decoupled inner platform and outer shell is used, then flexibility for different materials and cooling configurations is improved, but assembly complexity increases
Solution Approach 1:
The blade is segmented into distinct modules with standardized connection interfaces that simplify assembly. The decoupled inner platform and outer shell are designed as separate modules with matching interfaces, allowing flexible material and cooling configuration selection while maintaining manageable assembly complexity through modular construction and standardized joining mechanisms.
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 modular design enhances component lifetime, reduces thermal deformation, optimizes cooling air usage, and allows for standardized blade production tailored to specific conditions, reducing oscillations and enabling efficient repair by replacing only damaged subcomponents.
Implementation Method 1
cooling passages which extend inside the blade airfoil for cooling the blade and are supplied with a cooling medium, particularly cooling air
Implementation Method 2
The feed hole, which extends obliquely upwards into the interior of the blade airfoil, opens into the outside space on the convex side of the shank
Implementation Method 3
provision is made around the mouth of the feed hole for a planar stiffening element which reaches beyond the direct vicinity of the feed hole, which stiffening is formed integrally on the shank
Data Source
Figure 1~3
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Figure 6
AI summary
The invention relates to a blade assembly on the basis of a modular structure, wherein the blade elements comprise at least a rotor blade airfoil, a footboard mounting part (214) and a heat shield. The elements have at its one ending means for the purpose of an interchangeable connection among each other, wherein the connection of the airfoil with respect to the other elements is based on a fixation in radial or quasi-radial extension compared to the rotor axis of the turbomachine. The assembling of the blade airfoil in connection with the footboard mounting part is based on a force-fit or form-fit fixation, or the assembling of the blade airfoil in connection with the footboard mounting part to each other is based on the use of a metallic and/or ceramic surface for the purpose of a friction-locked bonding actuated by adherence interconnecting, or the assembling of the blade airfoil in connection with the footboard mounting part is based on friction-locked means with a detachable, permanent or semi-permanent fixation. At least the blade airfoil comprises at least a flow-charged outer hot gas path liner (200) which encases at least a part of the basic blade airfoil or basic sub-structure (210) of the blade airfoil.