Rotor Sealing Fin Caulking With a Synchronized Pressing Roller
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Solution Overview
Problem
Existing methods for fixing sealing fins to rotors in rotary machines are inefficient, leading to variations in pullout strength and requiring extensive time and labor, with manual caulking processes being prone to errors and instability in trajectory alignment.
Innovation Solution
A sealing fin fixing apparatus comprising a headstock, Z-stage, X-stage, tool rest, and caulking tool with a pressing roller, which allows for precise positioning and rotation of the rotor to consistently caulk the caulking wire into the sealing groove, minimizing variations in pullout strength and reducing installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual caulking with chisel or air hammer is used, then the sealing fin can be fixed to the rotor, but it takes excessive time and labor for installation
Solution Approach 1:
The patent replaces manual mechanical caulking (chisel/air hammer) with an automated caulking device that uses a rotating roller to apply consistent radial force. The device mechanically presses the caulking wire into the sealing groove while the rotor rotates, eliminating manual intervention and significantly reducing installation time.
Solution Approach 2:
The patent changes the caulking method from intermittent manual hammering to continuous rotational pressing. The rotating roller maintains constant contact with the caulking wire, applying steady radial pressure throughout the rotation, which transforms the caulking process from discrete impacts to continuous deformation, improving efficiency and consistency.
2Reliability
If peening device hits caulking wire against rotating rotor, then caulking can be performed, but the press-fit distance varies circumferentially causing variations in pullout strength
Solution Approach 1:
The patent transitions from a static peening device to a dynamic rotating roller system. The roller rotates synchronously with the rotor, maintaining constant angular relationship and consistent radial pressure throughout the caulking process. This dynamic synchronization eliminates the circumferential variations in press-fit distance that occur with stationary peening devices.
Solution Approach 2:
The rotating roller system automatically compensates for rotor rotation and maintains consistent caulking pressure without external adjustment. The roller's rotation is driven by the rotor itself, creating a self-regulating system where the caulking force is automatically applied at the correct radial position throughout each rotation, ensuring uniform press-fit distance.
3Productivity
If high rotational speed is used for caulking, then installation time is reduced, but the accuracy of trajectory alignment deteriorates
Solution Approach 1:
The patent uses synchronized rotation where the roller and rotor rotate together at the same speed. This dynamic coupling maintains precise angular alignment between the roller's pressing trajectory and the rotor's sealing groove throughout high-speed operation, eliminating trajectory errors that would occur with fixed-position devices at high speeds.
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
The apparatus efficiently fixes sealing fins to rotors in a shorter time, reduces variations in pullout strength, and enhances the reliability and accuracy of the sealing process, thereby improving the sealing performance and reducing operational costs.
Implementation Method 1
the pressing roller being held against the caulking wire inserted, together with the sealing fin, in the sealing groove in the rotor that is set on the headstock, the headstock being actuated to rotate the rotor, thereby caulking the caulking wire
Data Source
AI summary
A sealing fin fixing apparatus can fix a sealing fin to a rotor in a shortened period of time to minimize variations of the pullout strength of the sealing fin. In the sealing fin fixing apparatus that fixes the sealing fin in a sealing groove defined in the outer circumference of the rotor of a rotary machine and includes a headstock for setting a rotor thereon, a Z-stage movable along a Z-axis, an X-stage movable along an X-axis, a tool rest supported on the X-stage, and a caulking tool mounted on the tool rest and including a shank and a pressing roller, while the pressing roller is being held against a caulking wire inserted, together with the sealing fin, in the sealing groove in the rotor that is set on the headstock, the headstock is actuated to rotate the rotor, thereby caulking the caulking wire to fix the sealing fin to the rotor.