Gas Turbine Rotor Disc Conformance Testing Apparatus
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Solution Overview
Problem
Current methods for testing the conformance of gas turbine rotor discs are time-consuming, lack precision, and are heavily dependent on manual operations, leading to inconsistent results and potential imbalances in the rotor, which can cause premature aging and increased costs due to corrective actions.
Innovation Solution
An apparatus featuring a turntable with distance meters and a radial runout sensor, controlled by a processing unit that synchronizes measurement signals to accurately detect and validate the profiles of Hirth toothing on rotor discs, reducing operator subjectivity and ensuring precise alignment and balancing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual colorant application and visual inspection methods are used, then the testing process is simple and quick to implement, but the measurement precision and reliability are insufficient due to operator subjectivity and manual operation variations
Solution Approach 1:
The patent replaces manual mechanical operations (colorant application with paintbrush, visual inspection with graduated lenses) with automated optical measurement systems. Distance meters and radial runout sensors automatically capture geometric data of Hirth toothing, eliminating operator subjectivity and manual positioning errors while achieving precise, repeatable measurements of tooth profiles and coupling surfaces.
Solution Approach 2:
The patent creates digital copies of the physical Hirth toothing geometry through optical scanning. Distance meters and radial runout sensors capture the actual tooth profiles and generate digital representations that can be precisely analyzed against nominal designs, replacing subjective visual evaluation with objective digital comparison and validation.
2Productivity
If manual testing operations are used, then the device complexity is low, but the productivity is reduced due to time-consuming testing processes and the need for re-testing when imperfections are detected
Solution Approach 1:
The patent enables continuous measurement of Hirth toothing geometry by rotating the disc on a turntable while distance meters and radial runout sensors continuously capture data throughout the rotation. This continuous scanning process eliminates the need for multiple discrete manual measurements and allows complete inspection of tooth profiles in a single operational cycle, significantly reducing testing time and improving production line efficiency.
Solution Approach 2:
The patent performs conformance testing of Hirth toothing geometry before the rotor assembly is completed and sent to installation centers. By detecting and validating tooth profiles during the manufacturing phase, the system identifies imperfections early when corrective actions are less costly, preventing time-consuming disassembly and re-testing that would be required if defects were detected later in the production process.
3Measurement precision
If visual inspection with graduated lenses is used, then the ease of operation is high, but the measurement precision is insufficient due to operator margins of discretion and subjective evaluation
Solution Approach 1:
The patent replaces simple visual inspection with graduated lenses with automated optical measurement systems. Distance meters and radial runout sensors objectively capture precise dimensional data of Hirth toothing, eliminating operator margins of discretion and subjective evaluation. The system automatically processes and validates measurements against nominal designs, providing consistent, repeatable results without requiring complex manual operational procedures.
Data Source
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AI summary
An apparatus for testing conformance of rotor discs of gas turbines includes: a turntable (12), rotatable about an axis (A) and configured to support a rotor disc (2) of a gas turbine in a measuring plane (M); an actuator (20), operable to rotate the turntable (12) about the axis (A); and a supporting structure (13), supporting a first distance meter (15) and a second distance meter (16) on opposite sides with respect to the measuring plane (M). The supporting structure (13) is adjustable to set a first working distance (Dl) of the first distance meter (15) and a second working distance (D2) of the second distance meter (16) with respect to the axis (A). In one embodiment the supporting structure comprises a first arm and a second arm, movable parallel to the measuring plane, the first distance meter and the second distance meter being supported by the first arm and by the second arm, respectively. In another embodiment the apparatus comprises a runout sensor connected to the supporting structure and arranged to operate parallel to measuring plane.