Sandwich Turbomachinery Base Plate for Strength and Vibration Damping
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Solution Overview
Problem
Current base plate structures for gas turbine engines are labor-intensive and costly due to complex lattice designs requiring extensive welding and painting, which limits positioning flexibility and increases noise from vibrations, while being cumbersome and heavy due to the need for substantial height for flexural and torsional strength.
Innovation Solution
A turbomachine base plate comprising an upper and lower metal plate with a hardened flowable intermediate layer, such as polymer or metal foam, bonded to the inner surfaces and a peripheral frame, reducing the need for welding and providing improved mechanical strength and noise damping, allowing for a more compact and lightweight design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a lattice structure is used to provide sufficient flexural and torsional strength, then the mechanical strength is improved, but the weight and complexity increase
Solution Approach 1:
The base plate employs a composite structure consisting of a lattice framework filled with concrete or grout material. This composite design allows the thin-walled lattice structure to achieve high flexural and torsional strength through the combined action of the metal framework and the filling material, while keeping the overall weight lower than a solid base plate of equivalent strength
Solution Approach 2:
The invention transitions from a traditional solid or thick-walled base plate design to a three-dimensional lattice structure with internal filling. By utilizing the vertical dimension and internal volume of the lattice structure, the design achieves enhanced mechanical properties without increasing the footprint, while the filling material provides additional strength without proportionally increasing weight
2Strength
If a lattice structure with substantial height is used to provide sufficient flexural and torsional strength, then the mechanical strength is improved, but the manufacturing complexity and time increase
Solution Approach 1:
The base plate is segmented into a modular lattice structure composed of standardized beams and columns that can be manufactured separately and then assembled. This segmentation allows for pre-fabrication of components, reduced welding complexity during final assembly, and easier quality control compared to monolithic base plates requiring extensive现场 welding
Solution Approach 2:
The concrete or grout filling material acts as an intermediary that bonds the lattice structure components together, supplementing the mechanical connection provided by welding. This intermediary material distributes loads more evenly across the structure and reduces the criticality of welding quality, thereby simplifying the manufacturing process
3Strength
If a lattice structure is used to support rotary machines, then the load capability is improved, but the positioning flexibility decreases
Solution Approach 1:
The lattice structure incorporates localized reinforcement and adjustable supporting elements at specific positions to accommodate different rotary machine locations. By concentrating structural enhancements only where needed rather than uniformly throughout the entire base plate, the design maintains positioning flexibility while providing sufficient load capability at required locations
4Strength
If the vertical dimension of the base plate is increased to provide sufficient flexural and torsional strength, then the mechanical strength is improved, but the transportability and cost increase
Solution Approach 1:
The composite lattice structure with internal filling achieves high mechanical strength with reduced vertical dimension compared to solid base plates. The lattice framework provides structural rigidity while the filling material contributes to load-bearing capacity, allowing for a more compact overall height that improves transportability without sacrificing strength
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 enhances mechanical strength and reduces noise by providing a monolithic sandwich structure with improved flexural and torsional performance, while simplifying manufacturing and reducing weight and noise, achieving comparable strength to traditional lattice structures with a lower vertical dimension.
Implementation Method 1
An intermediate layer made of a filling material is arranged between the upper plate and the lower plate and is bonded to the inner surfaces of the upper and lower metal plates
Implementation Method 2
The flowable material can be an expandable material, e.g. a polymer foam, or a metal foam or a ceramic foam. Expansion of the foam material can efficiently fill the entire inner volume of the base plate structure
Data Source
AI summary
A turbomachine base plate is disclosed. The base pate includes an upper metal plate and a lower metal plate. The upper metal plate forms a turbomachine supporting surface. The base plate further includes an intermediate layer between the upper metal plate and the lower metal plate and bonded thereto. A frame extends peripherally around the intermediate layer.