Compressor Rotor Bore Tooling for Stable Stage Destacking

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Solution Overview

Problem

Current tooling used for disassembling gas turbine engine rotor stages can slip or move during operation, potentially damaging the costly integral-bladed rotors, necessitating extensive repair or replacement.

Innovation Solution

A disassembly tool with legs and a puck configuration that securely engages with the rotor bore, utilizing keys to lock into a groove, providing a stable reaction surface for applying an axial force to separate rotor stages without damaging them.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If conventional tooling is used to apply high pulling force to separate rotor stages, then the rotor stages can be disassembled, but the tooling may slip or move and damage the rotor stages

Engineering Contradiction:

Improvepulling forceVSAvoiddamage to rotor stages

Core Design Contradiction:

ForceVSObject-affected harmful factors

Solution Approach 1:

The disassembly tool is divided into multiple legs (typically three) that are distributed around the rotor bore perimeter. Each leg independently engages with the rotor bore through a groove, distributing the high pulling force across multiple contact points rather than concentrating it at a single location. This segmentation prevents slippage and reduces the risk of damage to the rotor stages during disassembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The legs are designed to be inserted through the rotor bore and nested within grooves formed in the rotor structure. The legs fit into these grooves like nested elements, creating a secure mechanical engagement that prevents slippage while allowing the application of high pulling forces. The pneumatic ram connects to the legs, which are themselves connected to the rotor bore through the groove engagement, creating a nested structural relationship.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Force

If high pulling force is applied to separate interference-fit rotor stages, then the stages can be separated, but the tooling may move during operation

Engineering Contradiction:

Improvepulling forceVSAvoidstability of tooling

Core Design Contradiction:

ForceVSStability of the object's composition

Solution Approach 1:

The tooling is segmented into multiple legs that are distributed around the rotor bore. This segmentation provides multiple stable engagement points with the rotor structure, preventing the tooling from moving or shifting during operation. Each leg independently maintains its position through groove engagement, ensuring overall tooling stability even under high pulling forces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The legs extend in multiple spatial dimensions - radially outward from the rotor bore center, axially along the rotor length, and circumferentially around the bore perimeter. This multi-dimensional configuration creates a stable three-point (or multi-point) engagement with the rotor structure, preventing movement in any direction during the disassembly operation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20250334060A1Compressor rotor destacking apparatus and method

Publication Date: 2025.10.30 RTX CORP

AI summary

A disassembly tool for a rotor assembly of a gas turbine engine includes a plurality of legs configured for installation into a rotor bore of a rotor of the rotor assembly. Each leg includes one or more keys extending radially inwardly toward a center of the rotor bore. A puck is configured for installation into the rotor bore radially inboard of the plurality of legs. The puck includes a groove receptive of the one or more keys to retain the puck to the plurality of legs.