Segmented Composite Shroud Notches for Axial Compressor Blade Clearance
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Solution Overview
Problem
The aerodynamic performance of segmented composite shrouds in axial compressors is compromised due to difficulties in resin injection, mold demolding constraints, and assembly processes, leading to increased clearance between shroud openings and blades, which negatively impacts compressor efficiency.
Innovation Solution
A modular shroud design featuring curved elements with notches that axially interlock with the blade profile, allowing for easier assembly and alignment, reducing the need for complex mold demolding and minimizing clearance between shroud openings and blades, thereby enhancing aerodynamic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the shroud is segmented into multiple sections for easier assembly and manufacturing, then the ease of manufacture and assembly is improved, but the aerodynamic performance deteriorates due to increased clearance between sections and blades
Solution Approach 1:
The shroud is divided into multiple curved elements that can be assembled separately and then joined together. Each curved element is designed with notches that correspond to blade contours, allowing precise positioning. The segmentation enables easier manufacturing and assembly while the notch design ensures minimal clearance when sections are joined, maintaining aerodynamic performance.
Solution Approach 2:
The invention introduces a new dimensional approach by creating notches that extend in the axial direction rather than only radially. This axial dimension allows the notches to accommodate blade profiles more effectively, reducing clearance issues that would otherwise occur with traditional radial-only segmentation approaches.
2Ease of operation
If the openings of the shroud are made larger to facilitate assembly of segmented sections, then the ease of operation is improved, but the aerodynamic performance deteriorates due to increased clearance
Solution Approach 1:
The opening is segmented into multiple notches along the axial direction, each notch corresponding to a specific blade. This allows the opening to accommodate blade profiles precisely without requiring excessive overall size, facilitating assembly while maintaining tight clearances for aerodynamic performance.
Solution Approach 2:
Different portions of the opening have different characteristics - the notches are sized and shaped specifically to match blade profiles locally, while the overall opening structure remains compact. This local optimization ensures both ease of assembly and minimal clearance throughout the opening area.
3Manufacturing precision
If the notches are designed to precisely fit the blade profile, then the aerodynamic performance is improved, but the device complexity increases due to more complex mold demolding requirements
Solution Approach 1:
The shroud is segmented into multiple curved elements that can be manufactured separately using simpler molds. Each element contains notches that precisely fit blade profiles, achieving high aerodynamic performance without requiring complex single-piece molds. The segmentation breaks down the manufacturing complexity into manageable sections.
Solution Approach 2:
The notches are pre-formed as integral parts of the curved elements during manufacturing, rather than requiring complex post-processing or assembly adjustments. This preliminary formation of precise notch geometries simplifies the overall manufacturing process while maintaining high precision for aerodynamic performance.
Data Source
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AI summary
The invention relates to a ferrule or ferrule section (8) for a vane-type rectifier stage of an axial compressor. The ferrule or ferrule section (8) is made of composite material and is constructed in two parts (12, 14), each comprising a series of notches (16, 18) corresponding to a profile of the vanes (4), so as to form openings that conform to the profile of the vanes when the two parts are assembled. The two parts also include means for mutual fastening (20, 21) for their assembly.