Rotor Axis Deviation Calculation via End Face Runout
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Solution Overview
Problem
Current methods for calculating axis deviation in aero-engine rotor assembly, such as the fitting plane method and actual rotary centerline method, face challenges in accuracy due to errors in fitting planes with irregular topography and limited adaptability to China's manufacturing level, particularly in ensuring concentricity and reducing part wear and time costs.
Innovation Solution
A method that calculates axis deviation based on end face runout measurement of flange joint surfaces before assembly, using a roundness meter to determine initial contact points and relative deviation matrices, which are then multiplied to obtain a total deviation matrix for optimizing assembly phases, thereby improving concentricity and reducing reassembly needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If fitting plane method is used to calculate assembly stacking deviation, then the processing algorithm is simple and can grasp the morphological characteristics of two joint surfaces as a whole, but the accuracy of the predicted axis deviation is difficult to be guaranteed due to large error between the fitting plane and source data for surfaces with double high points or irregular topography
Solution Approach 1:
The patent segments the joint surface into multiple measurement points and identifies specific contact point regions rather than using a unified fitting plane for the entire surface. This segmentation allows accurate representation of irregular topography with double high points while maintaining manageable computational complexity through localized analysis.
Solution Approach 2:
The patent applies different analysis approaches to different regions of the joint surface, specifically identifying and analyzing contact point regions with distinct topographic features (double high points) separately from other areas. This local quality approach ensures accurate axis deviation prediction for critical regions while maintaining overall processing efficiency.
2Measurement precision
If actual rotary centerline method is used to predict axis deviation, then the prediction accuracy is high, but it is difficult to adapt to the production and assembly process of aero-engine rotors in China due to restricted advanced part and component manufacturing level and widespread part out-of-tolerance phenomenon
Solution Approach 1:
The patent modifies the measurement and analysis parameters to accommodate out-of-tolerance parts by focusing on relative runout measurements between mating surfaces rather than absolute precision requirements. This parameter change allows the method to achieve sufficient accuracy even when individual parts exceed traditional tolerance specifications.
Solution Approach 2:
The patent performs preliminary measurement and analysis of joint surface topography before assembly to identify contact point characteristics and predict axis deviation in advance. This preliminary action allows for pre-adjustment of assembly parameters, making the method adaptable to varying manufacturing quality levels.
3Manufacturing precision
If trial-and-error assembly is used to ensure concentricity, then the assembly concentricity can be achieved, but the time and labor cost increase significantly
Solution Approach 1:
The patent performs preliminary measurement of joint surface runout and calculation of assembly stacking deviation before actual assembly. This preliminary action provides predictive information about axis deviation, allowing operators to pre-adjust assembly parameters and avoid repeated trial-and-error attempts, thereby significantly reducing assembly time and labor cost while ensuring concentricity.
Data Source
AI summary
A method for calculating axis deviation of rotor assembly based on end face runout measurement comprises three parts: calculation of three contact points, a triangle judgment criterion and a homogeneous coordinate transformation algorithm of a deviation matrix. Based on the measured end face runout data in production practice, the method realizes the prediction of axis deviation before assembly, improves the concentricity of rotors after assembly, also greatly increases the one-time acceptance rate of assembly and has important practical guiding significance for axis prediction as well as assembly phase adjustment and optimization in the assembly process of aero-engine rotor pieces.