Segmented Rotor Protection Casing for Transport Damage Prevention
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Solution Overview
Problem
Gas turbine engine rotors, particularly those made using additive manufacturing techniques, are prone to damage during transportation due to improper handling, with thin vanes being highly susceptible to deformation or breakage, and current methods lack effective repair solutions.
Innovation Solution
A protective casing with two segments and a latch mechanism, formed through additive manufacturing, that surrounds and secures the rotor using bias loads from spring plugs and spring beds to prevent damage, allowing for reuse before and after mechanical post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing techniques are used to create gas turbine engine rotors with thin vanes, then manufacturing complexity and design flexibility are improved, but susceptibility to damage during transportation and handling increases
Solution Approach 1:
The protective casing is divided into multiple segments that can be assembled around the rotor component. This segmentation allows the casing to be opened for loading/unloading the rotor while providing complete protection when closed, addressing the vulnerability of thin-vaned rotors during transportation.
Solution Approach 2:
The bias means (springs) are pre-loaded to apply continuous protective force to the rotor, particularly to the thin vanes, before any damage can occur during handling. This preliminary anti-action prevents deformation and breakage by counteracting potential harmful forces.
2Manufacturing precision
If mechanical post-processing is performed on AM rotors, then manufacturing precision is improved, but the risk of damage during handling between fixturing increases
Solution Approach 1:
The protective casing is designed to be used throughout the entire process from additive manufacturing through mechanical post-processing. The bias means are engaged beforehand to provide continuous protection during all handling operations between fixturing operations, preventing damage before it can occur.
Solution Approach 2:
The casing incorporates flexible bias means (springs) that can adapt to the rotor geometry while providing consistent protective contact. This flexibility allows the casing to accommodate the rotor during various handling positions without causing stress concentrations that could lead to damage.
3Reliability
If protective casings are designed to fully surround damage susceptible portions, then protection effectiveness is improved, but device complexity increases
Solution Approach 1:
The casing is segmented into multiple parts that can be assembled around the rotor, allowing complete surrounding protection of damage-susceptible portions while keeping individual segments manageable in complexity. The segmentation enables the casing to conform to the rotor geometry without requiring a monolithic complex structure.
Solution Approach 2:
The bias means serve multiple functions: they provide protective force to prevent damage, maintain contact between the casing and rotor, and accommodate variations in rotor geometry. This multi-functionality reduces the need for additional complex components while achieving comprehensive protection.
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 casing effectively protects gas turbine engine rotors from damage during transport by securing them with bias loads, ensuring they remain intact for further processing, and can be reused multiple times.
Implementation Method 1
a first bias means configured to impart a bias load to a first surface of a gas turbine engine component
Data Source
AI summary
A component protection casing includes a first segment that includes a first bias means configured to impart a bias load to a first surface of a gas turbine engine component, a second segment that includes a second bias means to impart a bias load to a second surface of the gas turbine engine component, and a latch mechanism configured to fasten the first segment to the second segment when the first segment and second segment are positioned in a closed configuration and the latch mechanism is engaged. The first segment and second segment are configured to receive and fully surround damage susceptible portions of a gas turbine engine component. The first bias load and second bias load are selected to secure the gas turbine engine component inside the component protection case when the first segment and second segment are positioned in a closed configuration and the latch mechanism is engaged.