Turbomachine Test Vane Modular Insert System
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Solution Overview
Problem
Current methods for testing turbine engine aerodynamic profiles are costly and time-consuming, requiring full disassembly and reassembly of test vanes, which complicates the manufacturing and machining processes, and imposes significant constraints on the number of tests that can be performed efficiently.
Innovation Solution
A modular insert system for turbine engine test vanes, where the insert fits into the vane body, allowing for quick and cost-effective changes between aerodynamic profile tests, reducing material usage and machining costs, and simplifying assembly and disassembly by reusing the vane body and changing only the insert for each test.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If full-scale test vanes are disassembled and reassembled for each aerodynamic profile test, then complete vane testing is achieved, but assembly time and manufacturing cost increase significantly
Solution Approach 1:
The test vane is divided into two main segments: a reusable body and interchangeable inserts. Each insert corresponds to a specific aerodynamic profile and can be independently removed and replaced without disassembling the entire vane structure. This segmentation enables rapid profile changes while maintaining complete vane functionality for each test configuration.
Solution Approach 2:
The aerodynamic profile-specific portions are extracted as separate inserts from the main vane body. These inserts contain the critical aerodynamic surfaces and can be independently handled, stored, and replaced. This extraction allows the reusable body to remain on the test bench while only the necessary profile components are changed.
2Reliability
If full-scale test vanes are manufactured for each aerodynamic profile, then complete testing capability is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The manufacturing process is segmented into two parts: a single reusable body that is manufactured once, and multiple inserts that are manufactured separately for different aerodynamic profiles. This reduces the overall manufacturing complexity by eliminating the need to manufacture complete vanes for each profile while ensuring each insert meets the required aerodynamic specifications.
Solution Approach 2:
The vane body is designed as a universal component that can accommodate multiple different inserts corresponding to various aerodynamic profiles. This multi-functionality allows a single body structure to support complete testing capability across different profiles, reducing the total number of components that need to be manufactured and managed.
3Reliability
If full-scale test vanes are disassembled for each test, then complete profile testing is achieved, but testing cost increases
Solution Approach 1:
By segmenting the vane into reusable body and interchangeable inserts, the system enables rapid profile changes without complete disassembly. This maintains testing accuracy for each aerodynamic profile while dramatically improving testing efficiency by reducing the time and resources required for setup between tests.
Solution Approach 2:
Multiple inserts for different aerodynamic profiles are prepared in advance and can be quickly swapped into the reusable body. This preliminary preparation eliminates the need for time-consuming disassembly and reassembly operations during the testing sequence, thereby improving productivity while maintaining complete testing capability.
Data Source
AI summary
The invention relates to an insert for a turbine engine test vane including the insert and a vane body. The insert includes at least two external surfaces. The insert is configured to fit into the vane body, such that the external surfaces are vane aerodynamic surfaces each forming part of a vane aerodynamic profile.