Rotor Assembly Airflow Nozzle for Fast Precision Cooling
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Solution Overview
Problem
The existing methods for assembling gas turbine engine rotors are hindered by the lengthy natural cooling process, which accounts for approximately 50% of the total assembly time, and previous attempts to use fans for cooling have been unsuccessful due to tight roundness and squareness requirements.
Innovation Solution
A cooling device with a circumferentially extending airflow nozzle, supported by adjustable rods, that directs uniform airflow to specific cooling locations on the rotor assembly, utilizing a manifold and airflow valves for precise control and monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If natural cooling is used for the rotor stack, then the cooling process is simple and does not affect rotor precision, but the cooling time is excessively long (approximately 1 hour per cooling cycle, 50% of total assembly time)
Solution Approach 1:
The patent applies pneumatic cooling by introducing compressed air through a cooling device positioned at the cooling location. The high-velocity airflow directly impinges on the heated rotor stack, rapidly removing heat through forced convection. This pneumatic approach reduces cooling time from approximately 1 hour to a fraction of that time, while the controlled airflow direction prevents distortion of the rotor's roundness and squareness tolerances.
2Loss of time
If fans are used for cooling the rotor stack, then cooling time is reduced, but the cooling method fails to meet tight roundness and squareness requirements
Solution Approach 1:
The cooling device is positioned specifically at the cooling location where heat accumulation occurs during assembly. The compressed air is directed precisely at this localized area rather than using general ambient cooling or fan-based approaches. This localized cooling approach efficiently removes heat from critical areas without creating uneven thermal gradients that would distort the rotor's dimensional tolerances.
Solution Approach 2:
The patent changes the cooling parameters by using high-velocity compressed air instead of low-velocity fan airflow. The compressed air provides significantly higher flow velocity and cooling intensity, enabling rapid heat removal. The controllable airflow parameters allow precise management of the cooling process to maintain rotor precision while dramatically reducing cooling time.
3Loss of time
If compressed air cooling is applied to accelerate cooling, then cooling time is reduced, but there is a risk of affecting rotor precision due to forced cooling
Solution Approach 1:
The system incorporates temperature sensors that continuously monitor the rotor stack temperature during the cooling process. This feedback information is used to control the compressed air flow rate and duration, ensuring the rotor cools to the appropriate temperature without excessive cooling that could cause thermal shock or distortion. The feedback mechanism allows dynamic adjustment to maintain precision while achieving rapid cooling.
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
This solution accelerates the cooling process, reducing assembly time while maintaining the required precision of the rotor assembly's roundness and squareness, thereby optimizing the assembly efficiency.
Implementation Method 1
a compressed air flow is directed at a cooling location of the rotor assembly to cool the rotor assembly
Data Source
AI summary
A cooling device for a rotor assembly of a gas turbine engine includes an airflow nozzle configured to be installed at a cooling location of the rotor assembly. The airflow nozzle extends entirely around a circumference of the rotor assembly and includes a plurality of airflow inlets and a nozzle outlet to direct an airflow toward the cooling location. An airflow source is operably connected to the plurality of airflow inlets.