Hydraulic Shaft Pre-Stretch Control for Accurate Component Connection
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Solution Overview
Problem
Existing manual systems for pre-stretching turbine shafts are not optimal due to the need for manual control of hydraulic pressure, which diverts the operator's attention from monitoring the overall status of the parts and hydraulic loading.
Innovation Solution
A method and system that automate the pre-stretching process by receiving a commanded pressure input, controlling hydraulic fluid pressure to initiate and measure the shaft's stretch, and determining if the stretch is within an acceptable range, with indicators and a controller managing the pressurization schedule and valve operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual control of hydraulic pressure is used to pre-stretch the shaft, then the operator can directly control the stretching process, but the operator's attention is diverted from monitoring the overall status of the parts and hydraulic loading
Solution Approach 1:
The system implements automated feedback control by using sensors to monitor shaft stretch in real-time and automatically adjusting hydraulic pressure based on measured values. The controller receives feedback from displacement sensors and pressure transducers, compares measured stretch against target values, and autonomously modifies hydraulic pressure to maintain precise control without requiring continuous operator intervention.
Solution Approach 2:
The system performs self-monitoring and self-adjustment functions through automated controllers that manage the entire pre-stretching process. The controller autonomously regulates hydraulic pressure, monitors sensor data, detects process completion, and manages safety interlocks without requiring continuous operator attention, allowing the operator to focus on higher-level monitoring tasks.
2Loss of information
If automated hydraulic pressure control is implemented, then the operator can focus on monitoring overall status, but the system complexity increases with controllers and sensors
Solution Approach 1:
The automated controller serves multiple functions simultaneously: it regulates hydraulic pressure, processes sensor data from multiple sources, performs calculations to determine shaft stretch, compares measurements against target values, controls valve operations, manages safety interlocks, and provides user interface operations. This multi-functionality consolidates what would otherwise require separate systems into a single integrated control unit.
Solution Approach 2:
The system introduces automated controllers and sensors as intermediary elements between the operator and the hydraulic system. These intermediaries handle the complex real-time control and measurement tasks, translating operator intent into precise hydraulic pressure adjustments and providing automated feedback about process status, thereby simplifying the operator's role while maintaining system precision.
3Productivity
If rapid pressurization is applied to achieve pre-stretch quickly, then productivity increases, but the shaft may be damaged due to excessive stress
Solution Approach 1:
The system dynamically adjusts hydraulic pressure based on real-time feedback from displacement sensors. The controller continuously monitors shaft elongation and automatically modulates pressure to keep the shaft within its elastic deformation range. This dynamic control allows the system to progress through different pressurization stages at optimal rates, maximizing productivity while preventing damage by automatically reducing pressure if the shaft approaches its yield point.
Solution Approach 2:
Real-time feedback from displacement sensors and pressure transducers enables the controller to monitor shaft response continuously during pressurization. The system uses this feedback to detect when the shaft is approaching its elastic limit and automatically adjusts pressure application rates accordingly, allowing rapid pressurization when safe and slowing down or stopping when the shaft nears its damage threshold.
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 automated system ensures accurate and efficient achievement of the commanded pressure, allows the operator to focus on other tasks, and provides real-time feedback on the acceptability of the shaft's stretch, thereby improving the precision and safety of the pre-stretching process.
Implementation Method 1
A hydraulic pump is configured to pump hydraulic fluid through a valve
Implementation Method 2
A measured stretch of the shaft is received from a sensor
Data Source
AI summary
A method of securing two components under this disclosure could be said to include receiving an input including a commanded pressure for achieving a pre-stretch on a shaft housed within a fixture. The shaft is coupled to a first component and extending through a second component. In response to receiving the input, causing hydraulic fluid to be provided to the fixture at a pressure based on the commanded pressure, to initiate the pre-stretch on the shaft. A measured stretch of the shaft is received from a sensor. Determining if the measured stretch is within a range of acceptable stretch; and based on a determination that the measured stretch is within the range of acceptable stretch, causing an indication of acceptability. The indication of acceptability being an instruction to tighten a nut to secure the shaft to the second component. A system and a controller are also disclosed.