Gas Turbine Rotor Assembly Intermediate Shaft Design
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Solution Overview
Problem
Conventional attachment mechanisms for gas turbine rotor assemblies result in significant axial length and weight, complicating manufacturing and component connection due to direct coupling with the turbine shaft.
Innovation Solution
A rotor assembly configuration featuring an intermediate shaft positioned radially between the turbine shaft and the second rotor, with a nut threadably engaged with the intermediate shaft to axially fix the first rotor between the nut and the second rotor, and bearing assemblies mounted on the intermediate shaft for improved stability and assembly access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional attachment mechanisms are used to assemble rotor assemblies, then the rotor assemblies can be manufactured and assembled, but the axial length and weight become significant
Solution Approach 1:
The rotor assembly is divided into multiple rotors (first rotor, second rotor, third rotor) that are stacked axially and connected through an intermediate shaft system. This segmentation allows each rotor to be manufactured separately and then assembled in a compact configuration, reducing the overall axial length compared to conventional single-piece or directly-coupled designs.
Solution Approach 2:
The intermediate shaft is positioned radially between the turbine shaft and the second rotor, creating a nested arrangement where components are arranged in radial layers rather than extending axially. The first rotor contacts and is mounted between the nut and the second rotor, further nesting components within the radial space to minimize axial length.
2Ease of manufacture
If conventional attachment mechanisms are used to assemble rotor assemblies, then the rotor assemblies can be manufactured and assembled, but the weight becomes significant
Solution Approach 1:
By segmenting the rotor assembly into multiple independently manufactured rotors connected through an intermediate shaft, the design eliminates the need for heavy conventional attachment mechanisms. Each segment can be optimized for its specific function, reducing overall material usage and weight while maintaining manufacturability.
Solution Approach 2:
The intermediate shaft acts as an intermediary component that connects the turbine shaft to the second rotor without requiring direct coupling. This intermediary approach allows for a more efficient load path and reduces the weight of attachment mechanisms compared to conventional direct-coupling methods.
3Ease of operation
If rotor assemblies are directly coupled to the turbine shaft, then the connection is straightforward, but manufacturing of rotor assembly mating features becomes more difficult and connection of rotor assembly components is complicated
Solution Approach 1:
The intermediate shaft serves as a mediator between the turbine shaft and the rotors, providing standardized mating features that are easier to manufacture than direct-coupling features. The intermediate shaft includes bearing assemblies and splined connections that simplify the manufacturing of rotor assembly mating features while maintaining straightforward connection procedures.
Solution Approach 2:
The design changes the geometric parameters of the connection interface by introducing the intermediate shaft with specific features (splines, bearing locations, mounting surfaces). These parameter changes make the mating features easier to manufacture through conventional processes while maintaining simple assembly procedures.
Data Source
AI summary
A rotor assembly for a gas turbine engine includes a turbine shaft disposed about a longitudinal axis, a first rotor and a second rotor configured for rotation about the longitudinal axis, and an intermediate shaft positioned radially between the turbine shaft and the second rotor. The second rotor is mounted to and axially adjacent the first rotor. The intermediate shaft is mounted to the turbine shaft on an inner radial side of the intermediate shaft. The intermediate shaft is mounted to the second rotor on an outer radial side of the intermediate shaft.