Turbomachine Rotor End Wall Contour Simplification
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Solution Overview
Problem
The existing rotor designs for turbomachines are complex and costly to produce, particularly in modernizing existing machines, due to the intricate three-dimensional shaping required for the end wall contours of rotor blades and intermediate pieces, which complicates the transition and assembly, potentially leading to incorrect assembly and flow impairment.
Innovation Solution
The end wall contour is simplified to have two turning points axially and merge tangentially into the rotor shaft, with a concave curvature that can be axially or circumferentially arranged, applied to both blade roots and intermediate pieces, ensuring symmetrical or asymmetrical designs for easy assembly and reduced production effort, and featuring radially directed support contours for secure fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex three-dimensional shaping is applied to the end wall contour of blade roots to improve gas flow stability, then flow stability is enhanced, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The rotor components are segmented into blade roots and intermediate pieces, both equipped with standardized end wall contours. This segmentation allows the complex flow stability function to be distributed across multiple simpler components rather than requiring intricate three-dimensional shaping of individual blade roots.
Solution Approach 2:
The invention changes the geometric parameters of the end wall contour from complex three-dimensional shapes to simpler two-dimensional contours with standardized curvature radii. This parameter simplification maintains the gas flow stability function while dramatically reducing manufacturing complexity.
2Reliability
If complex three-dimensional shaping is used for the end wall contour, then gas flow stability may be improved, but production effort and cost increase
Solution Approach 1:
The standardized end wall contour design serves multiple functions: it provides gas flow stability, enables simple manufacturing, facilitates correct assembly through symmetry, and allows retrofitting of existing turbomachines. This universal design approach eliminates the need for complex component-specific contours.
Solution Approach 2:
The invention employs simpler, more economical end wall contour designs that can be manufactured at lower cost. While the contours are not disposable, the simplified geometry enables cost-effective production and replacement of rotor components.
3Reliability
If asymmetric end wall contours are used to optimize gas flow, then flow characteristics improve, but assembly complexity and risk of incorrect assembly increase
Solution Approach 1:
The invention intentionally uses symmetric end wall contours rather than asymmetric ones. This symmetry simplifies assembly operations and eliminates the risk of incorrect assembly, while still achieving the desired gas flow characteristics through the standardized contour geometry.
Solution Approach 2:
The symmetric end wall contour design creates equipotential conditions for assembly, where any rotational position of the component yields the same functional result. This eliminates assembly complexity and ensures correct installation without requiring precise orientation.
4Reliability
If curved end wall contours are added to existing turbomachines during modernization, then performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The standardized end wall contour design is prepared in advance with fixed geometric parameters, enabling pre-manufacturing of rotor components. This preliminary preparation simplifies the modernization process, as components can be manufactured off-site and installed without complex on-site fabrication.
Solution Approach 2:
The standardized end wall contour acts as an intermediary element that bridges existing turbomachine designs with improved performance requirements. By providing a universal interface geometry, it enables straightforward retrofitting without requiring complex custom modifications to each existing machine.
Data Source
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Figure 3~5
AI summary
The rotor has moving blades (8) that are located adjacent to one another in a circumferential direction (19) with respect to rotation axis. Several intermediate pieces (14) are provided in reception slot between two adjacent ones of moving blades. Each intermediate piece is provided with an outer face having curved end wall contour (17) with concave curvature in an axial sectional plane of rotor. The outer faces (15,17) of blade roots (13) and intermediate pieces are adjacent to one another and are aligned radially in the circumferential direction. An independent claim is included for method for modernizing rotor of turbomachine.