Rotor Balancing via Centerline Deviation Calculation
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Solution Overview
Problem
Current methods for balancing bladed rotors in gas turbine engines are inefficient and lack consistency due to a trial-and-error approach, which fails to ensure optimal alignment and balance, leading to vibration and noise issues.
Innovation Solution
A computer-based method and system that calculates the best-fit stack of discs and optimal blade or bolt-and-washer distribution about the centerline of rotation, determining centerline deviations and angular locations to achieve precise balancing of rotor assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate balancing of each disc or component is performed using trial-and-error method, then individual components can be balanced, but the overall rotor assembly cannot achieve optimal alignment and balance
Solution Approach 1:
The method segments the rotor assembly into individual components (discs, blades, hubs) and measures each component's centerline deviation separately. By calculating and recording the centerline deviation of each component relative to its own centerline, the system enables precise tracking and compensation of each segment's misalignment, ultimately achieving optimal overall balance through systematic accumulation and correction of individual deviations.
2Manufacturing precision
If trial-and-error blade distribution is used, then some acceptable balance may be achieved, but consistency and repeatability are missing
Solution Approach 1:
The system performs preliminary measurement and calculation of centerline deviations for all rotor components before final assembly. By pre-calculating the optimal blade distribution based on measured deviations and determining the required balancing weights in advance, the method eliminates iterative trial-and-error adjustments during assembly, thereby improving both balance quality and operational efficiency.
Solution Approach 2:
The method incorporates feedback by measuring actual centerline deviations of rotor components and using this data to calculate precise blade distribution and balancing weight requirements. This closed-loop approach ensures consistent and repeatable results by basing decisions on measured data rather than arbitrary adjustments.
3Manufacturing precision
If multiple rotor discs are aligned using separate centerlines, then individual disc pairs can be aligned, but adding a third disc becomes impractical to align with all previous centerlines
Solution Approach 1:
The method merges all individual component centerlines into a unified reference system by calculating each component's deviation relative to its own centerline and then accumulating these deviations systematically. This approach consolidates multiple alignment references into a single coherent framework, allowing any number of discs to be aligned consistently without increasing procedural complexity.
Data Source
AI summary
A computer method or corresponding system for optimally balancing a rotor assembly. The computer system defines a theoretical centerline based on a mathematical model of the rotor assembly. For each disc or component of the rotor assembly, the invention system calculates rotor blade or bolt and washer distribution, based on calculated centerline deviations and angular locations of the discs and effective weights of rotor blade or bolt-and-washer sets. The rotor blade or bolt-and-washer distribution provides locations for placement of the rotor blades or bolts-and-washers so as to offset the centerline deviations and thus correct imbalance of the rotor assembly.