Turbine Blade Structural Segment Optimization

Solution Overview

Problem

The existing manufacturing process for turbine blades is inefficient, requiring numerous iterations of design modifications, physical testing, and simulations to achieve optimal thermal, aerodynamic, and structural dynamic responses, due to the highly interdependent and non-linear variables influencing airflow, thermal, and aerodynamic properties.

Innovation Solution

The introduction of a structural segment with a defined Frequency Factor (Ff) that considers the modulus, moment of inertia, and area of the blade, allowing for the selection of anisotropic materials and structural elements to optimize thermal, aerodynamic, and structural dynamic responses, thereby reducing the need for extensive testing and redesign.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional manufacturing processes for turbine blades are used, then design flexibility and performance optimization are possible, but the process requires numerous iterations of design modifications, physical testing, and simulations, resulting in high time and cost consumption

Engineering Contradiction:

Improvestructural dynamic response optimizationVSAvoidtime for design iterations and testing

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies parameter changes by introducing a frequency factor (Ff) that combines modulus, area, and moment of inertia into a single optimization parameter. By adjusting these parameters to achieve Ff between 1 and 1.4, the invention reduces the need for numerous design iterations and physical testing, directly addressing the time consumption issue while maintaining manufacturing precision for structural dynamic response optimization.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses computational modeling and simulations to create virtual copies of turbine blade designs before physical manufacturing. This allows multiple design iterations and performance optimizations to be tested in silico, reducing the need for repeated physical prototypes and testing, thereby significantly cutting down time and cost while maintaining design flexibility.

Inventive Principle:

Principle #26Copying

2Manufacturing precision

If traditional manufacturing processes for turbine blades are used, then design flexibility and performance optimization are possible, but the process requires numerous iterations of design modifications, physical testing, and simulations, resulting in high cost consumption

Engineering Contradiction:

Improvestructural dynamic response optimizationVSAvoidcost of design iterations and testing

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by introducing a frequency factor (Ff) that combines modulus, area, and moment of inertia into a single optimization parameter. By adjusting these parameters to achieve Ff between 1 and 1.4, the invention reduces the need for numerous design iterations and physical testing, directly addressing the cost consumption issue while maintaining manufacturing precision for structural dynamic response optimization.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses computational modeling and simulations to create virtual copies of turbine blade designs before physical manufacturing. This allows multiple design iterations and performance optimizations to be tested in silico, reducing the need for repeated physical prototypes and testing, thereby significantly cutting down cost while maintaining design flexibility.

Inventive Principle:

Principle #26Copying

3Power

If turbine blade designs are optimized for higher horsepower and speeds, then power output increases, but centrifugal stress on disks, blades, and roots increases, requiring very careful checking for lateral critical speeds, torsional critical speeds, radial bearing stabilities, and permissible flange loadings

Engineering Contradiction:

Improvehorsepower outputVSAvoidcentrifugal stress on rotor components

Core Design Contradiction:

PowerVSStress or pressure

Solution Approach 1:

The patent applies parameter changes by optimizing the frequency factor (Ff) to a specific range (1-1.4), which adjusts the structural properties of the turbine blade to better withstand centrifugal stresses. This allows higher horsepower and speeds to be achieved while maintaining structural integrity through controlled parameter adjustments rather than extensive redesigns.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies preliminary action by performing computational checks and optimizations of the frequency factor during the design phase, before manufacturing and physical testing. This preliminary optimization of structural parameters ensures that the blade can handle higher power outputs with reduced risk of centrifugal stress failures, minimizing the need for later redesigns and careful re-checking during testing phases.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12091985B2Engine component with structural segment

Publication Date: 2024.09.17 GENERAL ELECTRIC CO

AI summary

An engine component for a turbine engine, the engine component comprising a wall bounding an interior; a panel portion defining a portion of the wall, the panel portion comprising: an outer wall; an inner wall spaced from the outer wall to define a wall gap; and a structural segment formed within the wall gap comprising at least one structural element. The apparatus formed from a method including calculating a factor and adjusting a variable until the factor is between a given range.