Turbine Adaptive Stage Manufacturing Precision Coupling
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Solution Overview
Problem
The existing manufacturing methods for adaptive stages in steam turbines often result in inaccurate coupling between components, leading to incomplete closure and suboptimal control of extraction pressure, while also being costly.
Innovation Solution
A method involving the machining of inner and outer blade rings to create coupling surfaces, followed by the attachment of coupling rings and removal of cover rings, allowing for precise alignment and rotation of the swivel ring with respect to the integral collar, utilizing Electro Discharge Machining for accuracy and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the swivel ring and integral collar are manufactured separately and then assembled, then the manufacturing process is simpler and more cost-effective, but the coupling accuracy between components deteriorates
Solution Approach 1:
The adaptive stage is divided into two main segments: a swivel ring containing leading portions of guide blades and an integral collar containing trailing portions. These segments are manufactured separately using cost-effective methods, then precisely coupled through专门设计的 coupling surfaces and定位 features that ensure high alignment accuracy while maintaining manufacturing simplicity
Solution Approach 2:
Coupling surfaces with precision定位 features serve as intermediaries between the swivel ring and integral collar. These coupling interfaces include定位 pins,定位 holes, and precision-machined surfaces that mediate the connection, ensuring accurate relative positioning while allowing separate manufacturing of the two main components
2Ease of manufacture
If the swivel ring and integral collar are manufactured separately, then manufacturing costs are reduced, but the alignment accuracy between leading portions and trailing portions deteriorates
Solution Approach 1:
The coupling surfaces and定位 features are pre-designed and pre-positioned on both the swivel ring and integral collar during their respective manufacturing processes. This preliminary action ensures that when the components are assembled, the alignment is automatically achieved with high precision, eliminating the need for costly post-assembly adjustments
Solution Approach 2:
The invention specifies precise geometric parameters for the coupling surfaces, including surface flatness, perpendicularity, and定位 feature tolerances. By controlling these parameters within tight tolerances during manufacturing, the alignment accuracy between leading and trailing portions is ensured while maintaining cost-effective separate manufacturing
3Ease of manufacture
If traditional manufacturing methods are used, then manufacturing costs are lower, but the extraction pressure control precision deteriorates
Solution Approach 1:
The precision coupling between swivel ring and integral collar creates a reproducible, accurate geometric relationship between leading and trailing portions. This precise copying of the intended blade geometry ensures that the extraction pressure control function is achieved with high precision while using cost-effective manufacturing methods for the individual components
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 method ensures a precise and accurate coupling between the swivel ring and integral collar, enhancing the control of extraction pressure and reducing manufacturing costs, while maintaining operational integrity.
Implementation Method 1
utilizing Electro Discharge Machining for accuracy and cost-effectiveness
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A method for manufacturing an adaptive stage (10) for a turbine comprises the steps of: - manufacturing a plurality of blades (20), each blade including a pressure side (23) and a suction side (24) extending from a leading edge (25) to a trailing edge (26), - fixing each blade (20) to an inner blade ring (31, 32) and an outer blade ring (41, 42), in order that the leading edge (25) and the trailing edge (26) extend from one to the other of the inner blade ring (31, 32) and the outer blade ring (41, 42), - fixing a first cover ring (51) and a second cover ring (52) between the inner blade ring (31, 32) and the outer blade ring (41, 42), the inner blade ring (31, 32) and the outer blade ring (41, 42) being interposed between the first cover ring (51) and the second cover ring (52).