Non-Integral Splitter Ring for Turbine Vane Assembly
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Solution Overview
Problem
Existing turbine engine designs face manufacturing difficulties and aerodynamic performance issues due to integral splitter rings, which are challenging to manufacture and maintain, especially when subjected to foreign object damage (FOD), and result in less controlled tolerances and higher replacement costs.
Innovation Solution
A non-integral splitter ring design for the aggregate vane assembly, where the splitter ring is separate from both the outer band and the bypass vane retention component, allowing for segmented retention and improved tolerances, easier replacement, and enhanced aerodynamic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an integral splitter ring design is used, then the structural integrity is improved, but the manufacturing difficulty and replacement cost increase significantly
Solution Approach 1:
The splitter ring is designed as a separate, standalone component rather than being integrated with the outer band or bypass vane retention component. This segmentation allows the splitter ring to be manufactured independently using optimized processes, reducing overall manufacturing difficulty while maintaining structural integrity through proper engagement features with the outer band and retention plate
2Strength
If an integral splitter ring design is used, then the structural strength is improved, but the tolerance control deteriorates
Solution Approach 1:
By separating the splitter ring from the outer band and bypass vane retention component, each part can be manufactured and assembled with controlled tolerances. The engagement features between the splitter ring, outer band, and retention plate allow for precise tolerance management without the cumulative tolerance issues that would arise from an integral design
3Strength
If an integral splitter ring design is used, then the structural integrity is improved, but the ease of repair and replacement deteriorates
Solution Approach 1:
The splitter ring is designed as a replaceable component that can be independently removed and replaced without replacing the entire outer band or bypass vane retention component. This is achieved through the engagement relationship with the outer band and retention plate, allowing for cost-effective repairs when the splitter ring is damaged by foreign object damage or other factors
Solution Approach 2:
The splitter ring is extracted as a separate functional element from the overall assembly, allowing it to be independently maintained and replaced. This extraction principle enables repair operations to focus only on the damaged splitter ring rather than requiring replacement of larger integrated structures
4Ease of manufacture
If a non-integral splitter ring design is used, then the ease of manufacture and replacement is improved, but the device complexity increases
Solution Approach 1:
While the splitter ring is a separate component, it is combined with the outer band and bypass vane retention component through engagement features that create a unified functional assembly. This merging approach maintains the manufacturing and replacement advantages of separate components while achieving the structural integrity and functional performance of an integrated design
Data Source
AI summary
An aggregate vane assembly includes a core vane assembly encircling a central longitudinal axis and having a plurality of core vanes each extending radially between an inner hub and an outer band. The aggregate vane assembly also includes a bypass vane assembly disposed on a radially opposite side of the outer band relative to the plurality of core vanes. The aggregate vane assembly also includes a splitter ring positioned proximate to the first forward end. The aggregate vane assembly also includes at least one retention plate overlapping a forward end of the at least one bypass vane along the central longitudinal axis and also overlapping at least a portion of the splitter ring along the central longitudinal axis.