Thrust Plate Assembly Labyrinth Seal Ratio Optimization
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Solution Overview
Problem
Conventional air cycle machines in aircraft environmental control systems face challenges in balancing operational efficiency, internal cooling, and reliability due to reduced airflow and internal leakage, which increase component loads and fuel consumption.
Innovation Solution
A thrust plate assembly with an annular body and a main bore seal, where the ratio of the outer diameter of the outer rim to the inner diameter of the main bore seal is between 3.94 and 3.96, is used to create a labyrinth seal and couple the thrust plate assembly to the turbine housing, enhancing airflow direction and reducing leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional ACM components are used with standard sealing arrangements, then the device complexity is lower and ease of manufacture is better, but internal leakage increases which reduces operational efficiency and increases fuel consumption
Solution Approach 1:
The patent applies parameter changes by optimizing the ratio of the outer diameter of the annular body to the inner diameter of the main bore seal within a specific range (3.94-3.96). This precise dimensional parameter optimization reduces internal leakage and improves operational efficiency without requiring complex sealing structures or additional components
Solution Approach 2:
The patent applies local quality by focusing sealing optimization at the critical interface between the annular body and main bore seal. Rather than implementing complex sealing throughout the entire ACM, the invention concentrates the sealing function at this specific location with precisely controlled dimensions, reducing overall device complexity while effectively addressing internal leakage
2Productivity
If standard ACM designs are used, then manufacturing and assembly are simpler, but airflow direction control is less effective leading to reduced operational efficiency
Solution Approach 1:
The patent achieves improved airflow direction control by optimizing the dimensional ratio parameter of the annular body outer diameter to main bore seal inner diameter. This parameter optimization within the range of 3.94-3.96 enhances airflow directionality and operational efficiency while maintaining compatibility with standard manufacturing capabilities
3Reliability
If internal leakage is increased to reduce component loads, then reliability improves, but operational efficiency decreases and fuel consumption increases
Solution Approach 1:
The patent resolves the contradiction between reliability and energy loss by optimizing the dimensional ratio parameter. The specific ratio range (3.94-3.96) achieves an optimal balance where internal leakage is sufficiently controlled to maintain operational efficiency and reduce fuel consumption, while still allowing adequate load distribution across components for reliability
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 thrust plate assembly improves airflow direction and reduces internal leakage, thereby enhancing operational efficiency and reducing fuel consumption by balancing component loads in air cycle machines.
Implementation Method 1
positioning a main bore seal in a main bore of the thrust plate assembly proximate a thrust shaft of the air cycle machine to establish a labyrinth seal
Data Source
AI summary
An aspect is a thrust plate assembly for an air cycle machine. The thrust plate assembly includes an annular body defined by an outer rim and a main bore. The annular body includes a nozzle side and a thrust bearing side. The nozzle side includes a nozzle region proximate the outer rim and a turbine rotor region proximate the main bore, where the outer rim has an outer diameter. The thrust plate assembly also includes a main bore seal installed in the main bore. The main bore seal has an inner diameter, where a ratio of the outer diameter of the outer rim to the inner diameter of the main bore seal is between 3.94 and 3.96.