Module Alignment Plates and Pins for Faster Turbine Package Assembly
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Solution Overview
Problem
The challenge in assembling gas turbine engines and their auxiliary components is the alignment and integration of modules with pre-installed auxiliary packages, which is time-consuming and requires significant on-site assembly work, including field welds and material handling.
Innovation Solution
A system and method for assembling modules using alignment pins and plates that allow for precise alignment and attachment of pre-installed auxiliary packages within structural steel-framed modules, enabling stackable and easily installable units that maintain alignment during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If modules are assembled on-site with pre-installed auxiliary packages, then integration capability is improved, but assembly time and complexity increase
Solution Approach 1:
The auxiliary packages are pre-installed within the module spaces before the modules are shipped to the site. This preliminary action eliminates the need for complex on-site installation of auxiliary components, reducing assembly time while maintaining integration capability. The modules arrive ready-to-assemble with all auxiliary packages securely positioned within their respective modules.
Solution Approach 2:
The system divides the overall gas turbine engine system into separate modular units, each containing its own auxiliary packages. This segmentation allows modules to be manufactured, tested, and shipped independently, then quickly assembled on-site. The modular structure with defined interfaces (plates and alignment features) enables rapid integration without requiring complex on-site fabrication or alignment work.
2Manufacturing precision
If precise alignment of auxiliary packages is achieved, then manufacturing precision is improved, but assembly complexity increases
Solution Approach 1:
Alignment plates and alignment pins serve as intermediary elements between modules to achieve precise alignment. The plates are fixed to the module frames at specific locations, and the pins fit into corresponding holes in the plates. This intermediary alignment mechanism ensures accurate positioning of auxiliary packages relative to each other across module boundaries without requiring complex direct alignment procedures between the packages themselves.
Solution Approach 2:
The alignment system is designed so that the alignment features (holes in plates, pins) automatically guide the modules into correct alignment during assembly. The physical geometry of the alignment features self-enforces the precise positioning, eliminating the need for complex measurement and adjustment procedures. The auxiliary packages inherently align through the module alignment without requiring additional alignment operations on the packages themselves.
3Ease of operation
If on-site field welds are minimized, then ease of operation is improved, but structural integrity may be compromised
Solution Approach 1:
All structural welding and structural integrity-critical connections are performed during module manufacturing before shipping. The auxiliary packages are pre-installed and pre-secured within their modules using permanent structural connections. This preliminary structural work ensures full structural integrity is achieved in the controlled manufacturing environment, eliminating the need for field welds while maintaining operational ease.
Solution Approach 2:
The system segments the structural connections into module-level connections (made during manufacturing with full structural integrity) and module-to-module connections (made during assembly). The alignment plates and attachment members create sufficient structural connection between modules without requiring field welds, as the pre-fabricated module interfaces are designed to transfer loads effectively through mechanical fastening alone.
Data Source
AI summary
A system for assembling modules includes a first module having a first set of columns defining a first space. A first column of the first module defines a first hollow interior. The system includes a second module having a second set of columns defining a second space. A first column of the second module defines a second hollow interior. The system includes a first plate fixed within the first hollow interior. The system includes an alignment pin coupled to the first plate. The system includes a second plate that has a hole to receive the alignment pin and is engaged with the alignment pin to position the second plate in an aligned position with respect to the first column of the module. The second plate is fixedly attached to the first column of the second module in the aligned position within the second hollow interior.