Turbomachine Module Docking with Multi-Position Laser Alignment
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Solution Overview
Problem
The assembly of multi-spool gas turbine engines, particularly the low-pressure turbine module on a high-pressure body, faces challenges due to the lack of visibility during the inter-shaft bearing mounting process, leading to risks of damage from hard contact and imprecise positioning, which can result in non-quality assemblies or damage to parts.
Innovation Solution
A method using a device with a laser beam emitter and target to ensure parallelism between the longitudinal axis of the first module and the displacement axis, allowing precise positioning and avoiding contact during docking, which includes supporting and suspending mechanisms for adjusting the modules and verifying the laser beam's centering at multiple axial positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional assembly methods without laser alignment are used, then the assembly process is simple and quick, but the positioning precision is insufficient leading to hard contact and potential damage to bearing components
Solution Approach 1:
The patent replaces complex mechanical measurement and positioning systems with a laser-based optical alignment system. The laser beam emitter projects a reference beam through the housing to align the shaft, eliminating the need for intricate mechanical gauges, rulers, and manual measurement procedures while achieving superior positioning precision.
Solution Approach 2:
The patent introduces a laser beam as an intermediary element to establish precise alignment between the housing and shaft. The laser beam serves as a visible reference that mediates the alignment process, allowing operators to accurately position components without direct physical contact or complex mechanical interfaces.
2Reliability
If laser alignment equipment is introduced to improve positioning precision, then the risk of hard contact is reduced, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent implements preliminary alignment using the laser beam before the actual assembly operation. The laser establishes the correct positional reference in advance, allowing operators to pre-position the shaft and housing components accurately before final assembly, thereby preventing costly rework and reducing overall assembly time despite the added alignment step.
Solution Approach 2:
The laser alignment system provides self-aligning capabilities where the visible laser beam automatically guides operators to the correct positioning without requiring complex external measurement equipment or multiple adjustment steps. The system serves itself by providing an intuitive visual reference that eliminates the need for additional alignment tools or procedures.
3Ease of manufacture
If manual centering techniques are used, then the assembly process remains simple, but the positioning accuracy is insufficient leading to assembly defects and potential part damage
Solution Approach 1:
The patent replaces manual mechanical centering techniques (such as using rulers, gauges, or visual estimation) with a laser-based optical system. The laser beam provides a precise, visible reference that is far more accurate than mechanical measurement tools while maintaining procedural simplicity through intuitive visual alignment.
Solution Approach 2:
The patent utilizes the visible light property of the laser beam to provide a clear visual indicator for alignment. The bright, concentrated laser spot creates a distinct visual reference that is easily observable and provides immediate feedback to operators, making the alignment process both simple and highly accurate without requiring complex instrumentation.
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 enables reliable and precise alignment of the shaft of the low-pressure module relative to the high-pressure body, minimizing the risk of hard contact and ensuring accurate assembly, thereby reducing the risk of damage and improving the quality of the assembly process.
Implementation Method 1
a laser beam emitter intended to be fixed to said first module and configured to emit a laser beam coinciding with a longitudinal axis of this first module
Data Source
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Figure 3
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AI summary
Method for assembling a turbomachine (1) by means of a device (10), the turbomachine comprising at least two modules (3) which are assembled by the insertion of a shaft of one of the modules into a housing of the other of the modules, the device comprising: means (11) for supporting a first of the modules, means (20, 21) for suspending a second of the modules and for moving this second module along an axis of movement (Z), a laser beam emitter (30) intended to be fixed to the said first module and configured to emit a laser beam (31) that coincides with a longitudinal axis (X) of this first module, and a target (40) intended to be fixed to the said suspension and movement means so that it can be moved along the said axis of movement, and so that in at least two axial positions on this axis which are distant from one another, a spot from the said laser beam is located at the centre of the said target, the method being characterized in that it comprises the steps of: a) positioning the said first module (3) on the said support means (11), b) fixing the said target (40) to the said suspension and movement means, c) determining a first axial position of the said target, for which position a spot from the said laser beam (31) is positioned at the centre of the said target, d) moving the said target along the said movement axis (Z), and e) determining a second axial position of the said target, for which position a spot from the said laser beam is located at the centre of the said target, so as to validate the parallelism between the said longitudinal axis (X) of the said first module and the said movement axis.