Turbofan Lubricant Manifold Interlocking Assembly
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Solution Overview
Problem
The existing manufacturing processes for oil manifolds in gas turbine engines are complex and costly, requiring time-consuming coring and finish machining, and there is a need for improved assembly and manufacturing techniques to enhance engine performance and efficiency.
Innovation Solution
A lubricant manifold design featuring a base plate with open channels and a cover plate secured through an interlocking interface with tabs and hooks, which simplifies assembly and eliminates the need for separate sealing features, allowing for a weld joint to form a lubricant seal, thereby reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional casting and machining processes are used to form passages in the oil manifold, then the lubricant passages can be formed with complex geometries, but the manufacturing process becomes time-consuming and costly
Solution Approach 1:
The manifold is divided into a base plate and a separate cover plate that can be manufactured independently using simpler processes, then assembled together to form the complete lubricant passage system
Solution Approach 2:
The base plate and cover plate are joined through welding to create a unified structure with integrated lubricant passages, combining the advantages of simple manufacturing with complex passage geometry
2Reliability
If the cover plate is attached to the base plate with separate sealing features, then the lubricant seal can be ensured, but the assembly complexity increases
Solution Approach 1:
The sealing function is integrated directly into the welded joint between the base plate and cover plate, eliminating the need for separate sealing components while maintaining seal integrity
Solution Approach 2:
The welded joint itself provides the sealing function, with the weld metal forming the seal between the mating surfaces of the base plate and cover plate
Data Source
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AI summary
A lubricant manifold for gear system of a turbofan engine includes a base plate defining an inlet, an outlet and a plurality of open channels. The open channels define a portion of a corresponding plurality of lubricant passages. A cover plate is attached to the base plate to complete the formation of the plurality of lubricant passages. An interlocking interface between the base plate and the cover plate secures the cover plate to the base plate.