Synchronizing Ring Surge Bumper for Gas Turbine Stall Control

Solution Overview

Problem

Gas turbine engines face challenges in controlling deflection of variable stator vanes during high power engine stalls, leading to potential engine shutdowns due to excessive ring deflection and loss of vane control, especially in high vane count stages where bumper mounting space is limited.

Innovation Solution

A synchronizing ring assembly with integrated surge bumpers of varying arc lengths and clevis bridge bracket attachment passages, which provide additional support and prevent further deflection during surge events by contacting the outer engine case, thereby maintaining vane control and engine stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional bumper assemblies are used in high vane count stages, then the synchronizing ring can be supported during normal operation, but the bumper mounting space is insufficient near the case split flange, leading to excessive ring deflection during surge events

Engineering Contradiction:

Improvering deflection control during surge eventsVSAvoidbumper mounting space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent transitions from two-dimensional bumper mounting (on the plane of the synchronizing ring) to three-dimensional integrated surge bumpers that extend radially outward from the ring. This dimensional change allows the surge bumpers to contact the outer engine case surface, utilizing the radial dimension to achieve surge protection without requiring additional mounting space on the ring itself.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The surge bumper functionality is merged directly into the synchronizing ring structure through integration. The surge bumpers are formed as integral extensions of the ring portions, eliminating the need for separate bumper assemblies and their associated mounting hardware. This merging resolves the space constraint by making the surge protection feature part of the ring's own geometry.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If more bumpers are added to the synchronizing ring, then ring deflection control improves, but the device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvedeflection control during surge eventsVSAvoidnumber of bumper assemblies

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The surge bumper functionality is merged directly into the synchronizing ring structure through integration. The surge bumpers are formed as integral extensions of the ring portions, eliminating the need for separate bumper assemblies and their associated mounting hardware. This merging resolves the space constraint by making the surge protection feature part of the ring's own geometry.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The synchronizing ring portions are constructed from composite materials (fiber-reinforced plastic matrix) that provide both structural integrity and the ability to form integrated surge bumpers. This composite construction allows the ring to maintain strength while accommodating the integrated surge bumper geometry, reducing overall device complexity compared to traditional metallic bumpers.

Inventive Principle:

Principle #40Composite materials

3Area of stationary object

If integrated surge bumpers are formed from the synchronizing ring portions, then mounting space requirements are reduced, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvebumper mounting spaceVSAvoidring portion geometry precision

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The synchronizing ring portions are constructed from composite materials (fiber-reinforced plastic matrix) that provide both structural integrity and the ability to form integrated surge bumpers. This composite construction allows the ring to maintain strength while accommodating the integrated surge bumper geometry, reducing overall device complexity compared to traditional metallic bumpers.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent specifies precise geometric parameters for the ring portions, including arc lengths (180 degrees each), radial dimensions, and surge bumper dimensions (2-5% of ring arc length). These controlled parameter changes enable manufacturable precision for the integrated surge bumpers while maintaining the space-efficient design.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP3789590B1Synchronizing ring surge bumper

Publication Date: 2022.08.31 RTX CORP

Figure 1
Figure 2
Figure 3

AI summary

A synchronizing ring assembly includes a synchronizing ring portion (130) that has a first and a second distal end (134), the first and the second distal end each form an integrated surge bumper (180).