Monolithic Lead Separator for Gas Turbine Engine Routing
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Solution Overview
Problem
Conventional gas turbine engine struts are limited in their ability to efficiently transfer multiple leads, such as wires and tubes, due to bottlenecks caused by standard compression fittings and potential damage from sharp edges, which restricts the number of components that can be routed to desired locations within the engine.
Innovation Solution
A monolithic lead separator is developed, comprising a primary lead tube and multiple secondary lead tubes connected at an intersection point with an instrumentation lead splitter, allowing for a larger number of leads to be routed without bottlenecks and minimizing damage, using additive manufacturing to create a smooth, continuous surface free from discontinuities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If standard compression fittings are used to route leads in conventional struts, then the structure is simple and easy to manufacture, but the number of leads that can be routed is limited due to bottlenecks
Solution Approach 1:
The lead separator divides the single lead path into multiple separate channels, allowing individual routing of multiple leads. The internal geometry is segmented into distinct pathways that guide each lead independently from the inlet to the outlet, eliminating bottlenecks caused by compression fittings.
Solution Approach 2:
The lead separator uses three-dimensional internal channels that route leads through multiple spatial dimensions rather than forcing them through a single planar compression fitting. This dimensional approach allows multiple leads to pass through the strut simultaneously without interference.
2Object-affected harmful factors
If conventional struts with compression fittings are used, then manufacturing is easier, but sharp edges cause potential damage to leads
Solution Approach 1:
The lead separator features locally optimized smooth surfaces at critical transition zones where leads change direction or pass through the structure. These localized smooth regions prevent damage without requiring the entire strut to be manufactured with equally complex precision.
Solution Approach 2:
The internal channels of the lead separator are designed with curved transitions rather than sharp angles. The rounded geometries eliminate sharp edges that could damage leads, providing gentle guidance through the strut while maintaining manufacturability through standard additive manufacturing processes.
3Loss of time
If multiple leads are routed through conventional compression fittings, then routing is simpler, but post-installation routing efforts increase due to breakage and bottlenecks
Solution Approach 1:
The lead separator is pre-configured with multiple dedicated channels during manufacturing, establishing the complete routing path before installation. This preliminary configuration eliminates the need for post-installation routing adjustments and prevents lead breakage that would require rework.
Solution Approach 2:
The lead separator acts as an intermediary component that receives multiple leads at its inlet and distributes them through separate internal channels to the outlet. This mediator structure protects leads from damage and ensures proper routing without requiring complex external fittings or post-installation adjustments.
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 monolithic lead separator enables the passage of a greater number of leads without breakage or bottlenecks, reducing post-installation routing efforts and ensuring a gentle transition, thus enhancing the efficiency and reliability of lead distribution within the gas turbine engine.
Implementation Method 1
At least a portion of the layer is selectively sintered based upon data that defines an instrumentation lead separator
Data Source
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AI summary
A monolithic lead separator includes a primary lead tube defining a primary channel, a plurality of secondary lead tubes formed monolithically with the primary lead tube, and an instrumentation lead splitter. A cap is positioned in an aperture in the instrumentation lead splitter in a fluid-tight manner. Each of the secondary channels intersects the primary channel. The instrumentation lead splitter is situated at the intersection of the primary channel and the secondary channels.