Rotatable Machine Blade Sequence Optimization
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Solution Overview
Problem
Gas turbine engines face issues with rotor imbalance and multiple pure tone noise due to geometric variations and flowfield disturbances, leading to premature failure and passenger discomfort.
Innovation Solution
A computer-implemented method and system that determines geometric parameters for each blade based on the ratio of inlet and outlet areas between adjacent blades, iteratively remapping the blade sequence to minimize moment weight vector sum and reduce noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fan blades are assembled using moment weight mapping to minimize rotor imbalance, then rotor balance is improved, but multiple pure tone noise persists due to geometric variations between adjacent blades
Solution Approach 1:
The patent changes the assembly parameters from only moment weight to a combination of moment weight and inlet area. By introducing the inlet area parameter into the blade assignment process, the system can control both the balance (through moment weight) and the geometric uniformity (through inlet area matching), thereby reducing multiple pure tone noise while maintaining rotor balance
Solution Approach 2:
The patent performs preliminary measurement and classification of blade parameters (moment weight and inlet area) before assembly. Blades are pre-sorted into groups based on their parameter characteristics, and the computer system pre-determines the optimal assignment sequence that satisfies both balance and noise reduction requirements before the actual assembly process begins
2Object-generated harmful factors
If blade geometry variations are reduced to minimize shock wave differences, then multiple pure tone noise is reduced, but rotor imbalance may increase due to moment weight differences
Solution Approach 1:
The patent introduces a dual-parameter control system that simultaneously considers both inlet area (for noise control) and moment weight (for balance control). The computer system optimizes the blade assignment to satisfy constraints on both parameters, finding an optimal trade-off that reduces noise while maintaining acceptable balance levels
Solution Approach 2:
The system performs preliminary classification of blades into groups based on both inlet area and moment weight parameters. The computer system then pre-calculates the optimal assignment sequence that balances both parameters simultaneously, preventing the need for post-assembly adjustments and ensuring both noise reduction and balance requirements are met
3Ease of manufacture
If traditional moment weight mapping is used for blade assembly, then assembly process is simple, but both rotor imbalance and multiple pure tone noise occur due to adjacent blade geometric differences
Solution Approach 1:
The patent replaces the traditional mechanical/manual blade assignment process with a computer-based optimization system. The computer automatically calculates the optimal blade sequence by considering both moment weight and inlet area parameters, eliminating the need for complex manual calculations and iterations while achieving superior results in both balance and noise reduction
Solution Approach 2:
The system creates a virtual model of the blade assembly process where different assignment sequences can be simulated and evaluated before actual assembly. The computer system copies blade parameter data, performs virtual assembly simulations, and identifies the optimal configuration, thereby simplifying the actual manufacturing process while ensuring optimal performance
Data Source
AI summary
A processor-implemented method of assembling a rotatable machine is provided. The machine includes a plurality of blades that extend radially outwardly from a rotor. The method includes determining a geometric parameter for each blade in a row of blades that is relative to a ratio, R of an inlet area and an outlet area of a predetermined volume defined between each pair of blades, determining an initial sequence map for the row of blades that facilitates minimizing a difference of R between circumferentially adjacent pairs of blades, and iteratively remapping the sequence of the blades to facilitate reducing a moment weight vector sum of the rotor to a value that is less than a predetermined value.