Composite Rotor Containment Shroud for Radial Expansion Control
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Solution Overview
Problem
Existing rotor containment structures in rotary machines, such as those in aircraft, face a challenge in achieving high strength-to-weight ratio while complying with safety regulations, as heavier containment materials increase the overall weight of the aircraft, and non-biased materials fail to maintain structural integrity under high centrifugal forces and thermal expansion.
Innovation Solution
A rotor containment structure incorporating a shroud reinforcement with a support scaffold and high strength-to-weight ratio materials, such as woven fibers and composite materials, is used to provide effective containment without significantly increasing weight, utilizing geometric retaining features like axial treads and radial risers to maintain structural integrity during thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If high strength-to-weight ratio materials are used for rotor containment, then the weight of the rotary machine is reduced, but the structural integrity and containment performance deteriorate under high centrifugal forces
Solution Approach 1:
The patent applies composite materials by combining a metal shroud with a woven fiber reinforcement layer. The metal shroud provides baseline structural strength while the woven fiber layer (made of high strength-to-weight ratio material) enhances containment performance. This composite structure achieves both weight reduction and improved structural integrity under centrifugal forces, resolving the contradiction between using lightweight materials and maintaining strength.
Solution Approach 2:
The patent applies local quality by selectively reinforcing specific regions of the shroud where containment is most critical. The woven fiber reinforcement is applied locally to the shroud surface rather than uniformly throughout the entire structure, providing enhanced strength precisely where needed to contain rotor fragments under centrifugal force while minimizing overall weight addition.
2Ease of manufacture
If non-bias materials are used for containment, then the manufacturing process is simplified, but the materials shift during operation due to thermal expansion mismatch
Solution Approach 1:
The patent applies parameter changes by selecting a woven fiber reinforcement material with thermal expansion characteristics that match or are compatible with the metal shroud. This parameter matching prevents relative movement between the reinforcement layer and the shroud during thermal cycling, eliminating the shifting problem while maintaining the manufacturing simplicity of applying a reinforcement layer to a formed shroud.
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 solution reduces the weight of the rotary machine while maintaining compliance with safety standards and ensuring consistent clearances, enhancing the efficiency and functionality of the aircraft by minimizing structural expansion and maintaining containment under high centrifugal forces.
Implementation Method 1
High strength-to-weight ratio materials have been used for containment in axial fans. Such coatings shift when the axial fans are running because the non-bias materials used do not stretch or expand with the containment pieces they coat.
Implementation Method 2
the non-bias materials used do not stretch or expand with the containment pieces they coat
Data Source
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AI summary
A containment structure for a rotor includes a shroud (116) and a shroud reinforcement (118). The shroud is coaxial with and partially surrounds the rotor (114) and includes a tubular section (130), a transition section (132), and a flange section (134). The tubular section extends axially past a first side (120) of the rotor. The transition section connects to the tubular section and is adjacent to a curved side (128) of the rotor. The flange section connects to the transition section opposite the tubular section. The flange section extends radially past a radially outer side (124) of the rotor. The shroud reinforcement is connected to a radially outer surface of the transition section. The shroud reinforcement encloses the transition section and includes a support scaffold (136) and a reinforcing material (142). The support scaffold includes a series of geometric retaining features encircling a radially outer surface of the transition section. The reinforcing material couples to the support scaffold and restricts shroud radial expansion.