Tandem Guide Vane Segment Assembly for Precise Overlap Alignment
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Solution Overview
Problem
Current methods for manufacturing tandem guide vane segments in gas turbines lack effective approaches for precise construction and integration, particularly in terms of vane overlap and gap management, which affects aerodynamic performance.
Innovation Solution
The method involves manufacturing an integral intermediate structure that includes the outer and inner platforms and guide vanes, followed by further processing to create the final shape and separate the guide vanes, using techniques like forging, casting, and cutting to achieve precise alignment and overlap configurations such as S-shaped or Z-shaped limiting lines for exact positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If guide vanes are manufactured separately and assembled, then manufacturing flexibility is improved, but alignment precision and positioning accuracy deteriorate
Solution Approach 1:
The guide vane assembly is segmented into front guide vane, rear guide vane, and platform components that can be manufactured separately using forging or casting, then precisely positioned and connected using S-shaped or Z-shaped limiting lines and connection elements to achieve both manufacturing flexibility and alignment precision
Solution Approach 2:
Connection elements and limiting lines serve as intermediaries between separately manufactured guide vanes and platforms, enabling precise positioning and alignment while maintaining the benefits of separate manufacturing. The S-shaped or Z-shaped limiting lines act as geometric mediators that define exact positions
2Manufacturing precision
If guide vanes are manufactured as an integral structure, then alignment precision is improved, but manufacturing complexity and processing time worsen
Solution Approach 1:
The integral structure is divided into manufacturable segments (front guide vane, rear guide vane, platforms) that can be produced separately using standard forging or casting processes, reducing manufacturing complexity while maintaining overall precision through controlled connections
Solution Approach 2:
Guide vanes and platforms are preliminarily manufactured as separate integral components using forging or casting, then subsequently connected with precise positioning. This preliminary separate manufacturing simplifies the overall process compared to creating one large complex integral structure
3Productivity
If gap between guide vanes is reduced, then aerodynamic performance is improved, but manufacturing precision requirements worsen
Solution Approach 1:
The connection elements and limiting lines act as intermediaries that precisely control the gap between front and rear guide vanes. These geometric features enable accurate gap management during assembly, achieving both small gaps for aerodynamic performance and controllable precision through the intermediary positioning mechanisms
4Productivity
If guide vanes overlap more, then aerodynamic performance is improved, but risk of protrusions and positioning errors worsens
Solution Approach 1:
S-shaped or Z-shaped limiting lines and connection elements serve as intermediaries that define and control the overlap configuration between guide vanes. These geometric intermediaries ensure proper positioning and prevent protrusions while enabling the desired overlap for aerodynamic performance
Solution Approach 2:
The limiting lines and connection design incorporate preliminary anti-action by pre-defining the maximum overlap limits and preventing protrusions before they occur. The geometric constraints built into the limiting lines proactively prevent positioning errors
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
This approach enables the production of tandem guide vane segments with precise alignment and overlap, preventing protrusions and allowing for exact positioning, thereby enhancing aerodynamic performance and manufacturing efficiency.
Implementation Method 1
the manufacturing of an integral intermediate structure is carried out by means of forging or casting
Implementation Method 2
the manufacturing of an integral intermediate structure is carried out by means of forging or casting
Implementation Method 3
the forming of the gap can be carried out by means of milling or by means of an erosion method
Implementation Method 4
for example a discharge machining method
Data Source
AI summary
Methods for manufacturing a tandem guide vane segment that includes an outer platform, a front guide vane, and a rear guide vane, wherein the front guide vane and the rear guide vane are arranged in a firmly fixated manner with respect to one another. One method includes manufacturing an integral front segment section that includes the front guide vane and a front section of the outer platform, manufacturing an integral rear segment section that includes the rear guide vane and a rear section of the outer platform, and connecting the two segment sections to each other.