Gas Turbine Rotor Blade Assembly Fixture
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Solution Overview
Problem
Current methods for assembling bladed rotors in gas turbine engines are inefficient, particularly in seating rotor blades into slots and inserting seal elements, which can be challenging due to the geometry of the components and require complex tools.
Innovation Solution
A method and fixture are provided where rotor blades are supported by a blade support structure that is lowered axially to seat attachments into slots on the rotor disk, utilizing gravity to facilitate the seating process, and seal elements are inserted between neighboring blades, with a fixture that includes a disk support structure and a blade support structure to guide and locate the rotor disk and blades accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex tools and methods are used to seat rotor blades and insert seal elements, then assembly precision can be maintained, but device complexity and assembly time increase
Solution Approach 1:
A blade support structure is introduced as an intermediary device to facilitate the seating of rotor blades and insertion of seal elements. This structure provides a stable platform that guides components into proper positions, eliminating the need for complex specialized tools while maintaining assembly precision.
Solution Approach 2:
The assembly fixture is designed to create equipotential conditions by providing a stable, level support structure that naturally guides components into their correct positions through gravity and geometric constraints, rather than requiring complex active control mechanisms.
2Productivity
If traditional assembly methods are used for seating rotor blades, then assembly can be performed with existing equipment, but assembly efficiency and productivity are reduced
Solution Approach 1:
The blade support structure combines multiple assembly functions into a single integrated fixture: supporting rotor blades, guiding attachment seating into slots, and facilitating seal element insertion. This merging of functions into one device significantly improves assembly efficiency compared to using multiple separate tools and procedures.
Solution Approach 2:
The fixture is designed to pre-position and guide components during assembly, performing preliminary alignment actions that would otherwise require time-consuming manual adjustments. The support structure is configured in advance to naturally guide blades and seals into their correct positions.
3Manufacturing precision
If manual methods are used to seat attachments into slots, then tool requirements are simple, but manufacturing precision and alignment are compromised
Solution Approach 1:
The blade support structure is divided into multiple segments or support points that independently guide different parts of the rotor blades and seal elements. This segmentation allows each part to be precisely positioned and aligned while maintaining ease of operation, as each segment can be independently adjusted or replaced.
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 method simplifies the assembly process by using gravity to seat rotor blades and insert seal elements, reducing the complexity of tools required and improving the efficiency of the assembly, ensuring proper alignment and seating of components.
Implementation Method 1
The attachments are simultaneously seated into the slots using a force of gravity alone to push the attachments into the slots
Data Source
Figure 1
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AI summary
A method is provided for assembling a rotor of a gas turbine engine. During this method, a rotor disk (24) is provided that includes an axis (22; 102) and a plurality of slots (60) arranged circumferentially about the axis (22; 102) in an array. A plurality of rotor blades (26) are provided that include a plurality of airfoils (64) and a plurality of attachments (66). Each of the rotor blades (26) includes a respective one of the airfoils (64) and a respective one of the attachments (66). Each of the attachments (66) is inserted partially into a respective one of the slots (60). The rotor blades (26) are rested on top of a blade support structure (106). The blade support structure (106) is lowered axially downward along the rotor disk (24) to simultaneously seat the attachments (66) into the slots.