Gas Turbine Rotor Assembly with Composite Reinforcement
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Solution Overview
Problem
Existing gas turbine engine rotor assemblies face challenges in efficiently managing centrifugal forces and maintaining structural integrity while minimizing weight, particularly in high-speed applications.
Innovation Solution
The rotor assembly incorporates a hybrid airfoil design featuring a metallic sheath and a composite core, with retention pins and annular flanges that distribute centrifugal loads effectively, and reinforcement members that enhance structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a traditional metallic rotor design is used, then structural strength is maintained, but weight increases
Solution Approach 1:
The patent applies composite materials by combining a metallic sheath with a composite core (such as carbon fiber reinforced polymer) in the airfoil construction. The composite core provides high strength-to-weight ratio, reducing overall rotor weight while maintaining structural integrity. The metallic sheath provides protective functions while the composite material handles primary load-bearing, achieving weight reduction without sacrificing strength.
Solution Approach 2:
The rotor assembly is segmented into distinct functional components: a metallic sheath providing protection and a separate composite core providing structural strength. This segmentation allows each material to be optimized for its specific function, with the composite core bearing centrifugal loads and the metallic sheath providing environmental protection, thereby reducing overall weight while maintaining strength.
2Strength
If airfoils are securely fastened to the hub, then structural integrity is maintained, but device complexity increases
Solution Approach 1:
The patent merges the fastening function with the airfoil root structure itself. The composite core of the airfoil is designed to integrate with the hub, eliminating the need for separate complex fastening systems. The airfoil root incorporates features that directly engage with the hub, combining the structural connection and fastening functions into a single integrated design, thereby reducing device complexity while maintaining connection strength.
3Strength
If reinforcement members are added to the hub, then structural support is enhanced, but device complexity increases
Solution Approach 1:
The patent applies local quality by positioning reinforcement members specifically at critical locations on the hub where centrifugal forces are highest, rather than uniformly strengthening the entire hub structure. The reinforcement members are strategically placed at the interface between the airfoils and hub to provide targeted structural support exactly where needed, enhancing local strength without adding unnecessary complexity to the overall hub design.
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 design achieves a balance between weight reduction and structural integrity, improving aerodynamic efficiency and durability against foreign object debris (FOD) impacts.
Implementation Method 1
the use of very high tensile strength fibrous composite wrap to reinforce the metal rotor drum against the very high centrifugal forces exerted upon it
Data Source
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AI summary
A rotor assembly (60, 360, 460, 560, 860, 960) for a gas turbine engine (20) includes a rotatable hub (62, 362, 462, 562, 662, 762, 862, 962) that has a metallic main body (62A, 362A, 562A, 762A, 862A) that extends along a longitudinal axis (X), and that has an array of annular flanges (62B, 362B, 462B, 562B, 762B, 862B, 962B) that extend about an outer periphery (62C, 362C 462C, 562C, 762C) of the main body (62A... 862A) to define an array of annular channels (62D, 362D, 462D, 562D, 762D, 862D) along the longitudinal axis (X). Each of the annular channels (62D... 862D) receives a composite reinforcement member (388, 488, 788, 888) that extends about the outer periphery (62C... 762C) of the hub (62... 962).