Gas Turbine Rotor Spline Engagement for Space-Constrained Torque Transmission
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Solution Overview
Problem
Existing gas turbine engine rotor assembly techniques face challenges in achieving optimal balance between cost, durability, maintenance, and weight, particularly in aircraft applications, where limited radial and axial space constraints complicate torque transmission and component integration.
Innovation Solution
A gas turbine engine rotor assembly utilizing a spline engagement between discs, where a male spline from one disc engages with a female spline on another, allowing for efficient torque transmission and additional space for sealing assemblies and air passages, facilitating a double spigot fit design and improved manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional rotor assembly techniques are used to connect discs, then structural strength is maintained, but available space for sealing assemblies and air passages is limited
Solution Approach 1:
The rotor assembly is segmented into multiple discs (first disc, second disc, third disc) connected through a spline shaft, allowing each component to be optimized independently while maintaining overall structural integrity. The spline engagement divides the torque transmission function across multiple engagement points, preserving strength while creating inter-disc space for sealing assemblies and air passages.
Solution Approach 2:
The spline shaft is nested within the spline engagement features of the discs, with sealing assemblies and air passages nested within the inter-disc space created by this arrangement. This nested configuration maximizes the use of available volume without compromising the structural connection between discs.
2Weight of moving object
If compact rotor design is implemented to reduce weight, then weight is reduced, but torque transmission efficiency may be compromised
Solution Approach 1:
The spline engagement provides a dynamic torque transmission mechanism that accommodates axial movements and misalignments while maintaining efficient power transfer. The male and female spline features engage flexibly, allowing the rotor to absorb operational variations without compromising torque transmission, thus maintaining power efficiency in a compact design.
Solution Approach 2:
The spline shaft acts as an intermediary element between the discs, facilitating torque transmission while enabling the compact arrangement. This intermediary component allows for optimized disc spacing and positioning, reducing overall rotor weight while maintaining effective torque transfer through the spline engagement mechanism.
3Volume of moving object
If multiple components are integrated into limited radial and axial space, then space utilization is improved, but manufacturing complexity increases
Solution Approach 1:
The spline shaft serves multiple functions simultaneously: it transmits torque between discs, provides structural support, enables positioning of sealing assemblies, and facilitates air passage routing. This multi-functionality reduces the need for additional separate components, simplifying manufacturing while maximizing space utilization.
Solution Approach 2:
The spline engagement features are merged directly into the disc structures, eliminating the need for separate coupling components. The sealing assemblies and air passages are integrated into the inter-disc space created by the spline arrangement, reducing part count and simplifying assembly procedures while maintaining efficient space utilization.
Data Source
AI summary
The rotor assembly can have a first disc having a first body extending circumferentially and radially around the axis, a first set of circumferentially distributed blades protruding radially from the first disc, and a male spline extending axially relative the first body, the male spline extending around and along the axis, and a second disc having a second body extending circumferentially and radially around the axis, a second set of circumferentially distributed blades protruding radially from the second disc, and a female spline extending around and along the axis, the female spline receiving the male spline in a spline engagement.