Multi-Ring Rotor Spacer for Turbine Stack Alignment Tolerance
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Solution Overview
Problem
Existing gas turbine engine rotor assemblies face challenges due to manufacturing variations causing varying thicknesses and angles of spacers, which affect rotor stack alignment and performance.
Innovation Solution
A multi-ring spacer system with adjustable rings that allow for precise alignment by varying the angular offset of the rings to match the kink angles and axial lengths of the as-manufactured engine components, using a combination of nominal and out of square rings to compensate for manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If classified spacers with varying thicknesses and angles are used to accommodate manufacturing variations, then adaptability to manufacturing tolerances is improved, but device complexity increases due to multiple spacer classes
Solution Approach 1:
The spacer is divided into multiple independent rings that can be selectively assembled. Each ring can be individually selected based on its thickness and angle characteristics, allowing the system to accommodate manufacturing variations without requiring a completely different spacer design for each case.
Solution Approach 2:
The spacer system transitions from a static, fixed-design approach to a dynamic, selectable approach. By allowing different ring combinations and clocking positions, the spacer system can adapt its effective thickness and angle to match the specific manufacturing variations of the rotor components it is installed between.
2Adaptability or versatility
If multiple classified spacers are used to achieve desired axial length, then adaptability is improved, but manufacturing precision requirements worsen due to cumulative tolerances
Solution Approach 1:
By segmenting the spacer into multiple rings, the system allows for selective assembly where each ring's dimensions can be independently controlled and measured. This segmentation enables better tracking and management of manufacturing tolerances for each individual ring rather than treating the entire spacer as a single component with cumulative tolerances.
Solution Approach 2:
The invention changes the approach from controlling a single spacer's parameters to controlling multiple rings' parameters independently. By allowing different clocking positions and combinations of rings with slightly varying thicknesses and angles, the system can achieve the desired overall axial length while accommodating individual manufacturing variations through parameter selection rather than requiring ultra-precise manufacturing of each component.
3Manufacturing precision
If best-fit matching is required for spacer selection, then manufacturing precision is improved, but ease of operation deteriorates due to complex selection processes
Solution Approach 1:
The rings are pre-manufactured with known and documented thickness and angle characteristics. This preliminary characterization of each ring allows for simplified selection during assembly, as the installer can choose rings based on pre-established criteria rather than performing complex measurements and calculations during the assembly process.
Solution Approach 2:
The segmentation into standardized rings with documented properties simplifies the selection process. Instead of requiring best-fit matching of a single complex spacer, the system allows selection from a set of simpler, standardized rings whose properties are already known, making the selection and assembly process more straightforward and easier to operate.
Data Source
AI summary
A multi-ring spacer includes a first ring having a first clocking position, a second ring coaxial with the first ring, and having a second clocking position. A total kink angle of the multi ring spacer is dependent on an angular deviation of the second ring's clocking position relative to the first ring's clocking position.