Unitary Gimbal Assembly for Pressurized Pipe Flexibility
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Solution Overview
Problem
Traditional gimbals used in gas turbine aircraft engines are limited by their design and manufacturing processes, which restrict size, strength, and fluid-carrying capabilities, often requiring skilled welding and resulting in component failures.
Innovation Solution
A gimbal design featuring a core portion and joint shield portion formed as a single unitary component through additive layer manufacturing, eliminating the need for welding and enhancing structural strength and fluid compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional extrusion, rolling and forming processes with welding are used to manufacture gimbals, then the manufacturing process is well-established and can be performed with traditional equipment, but the gimbal strength is insufficient to contain pressurized liquids and components often fail at weld joints
Solution Approach 1:
The patent combines multiple previously separate components (core portion, joint shield portion, flexible portion, joint cover portions) into a single unitary structure manufactured by additive layer manufacturing. This eliminates the need for welding between these components, removing the weak points at weld joints while maintaining manufacturability through modern additive processes.
Solution Approach 2:
The patent transitions from traditional subtractive and formative manufacturing methods to additive layer manufacturing. This parameter change in the manufacturing process enables the creation of complex geometries with inherent structural strength that can contain pressurized liquids, while eliminating welding operations that previously caused component failures.
2Adaptability or versatility
If traditional manufacturing processes are used, then the production method is established and relatively simple, but the gimbal design is restricted in size, design flexibility and strength
Solution Approach 1:
The patent segments the gimbal into functional portions (core portion, joint shield portion, flexible portion, joint cover portions) that are designed separately but manufactured as a unified structure through additive layer manufacturing. This allows independent optimization of each portion's geometry for its specific function while achieving integration that eliminates welding and assembly complexity.
Solution Approach 2:
The patent utilizes additive layer manufacturing to create three-dimensional complex geometries that cannot be achieved with traditional extrusion, rolling, and forming processes. This dimensional capability enables optimized structural shapes, internal reinforcement features, and integrated protective covers that enhance design flexibility and strength without proportionally increasing manufacturing complexity.
3Reliability
If multiple separate components are used in the gimbal assembly, then the gimbal can be manufactured using traditional processes, but the part count is high and welding is required which reduces reliability
Solution Approach 1:
The patent merges multiple discrete components into a single unitary structure manufactured by additive layer manufacturing. This eliminates all weld joints between the core portion, joint shield portion, flexible portion, and joint cover portions, removing the primary failure points and significantly improving reliability while reducing the effective part count from 12 sub-components to one integrated component.
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
The solution reduces part count, improves strength, and allows for flexible design and fluid handling, making it suitable for pressurized liquids, while minimizing maintenance and stress resistance.
Implementation Method 1
The core portion and the or each joint shield portion are formed as a single unitary component by an additive layer manufacturing process
Implementation Method 2
the or each flexible portion has a degree of flexibility to allow movements between the first duct and the second duct
Data Source
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AI summary
A gimbal for connecting pipes. The gimbal has a core portion and at least one joint shield portion that surrounds the core portion. The core portion, which has a core portion internal surface and a core portion external surface, has and at least two pipe engaging portions that are separated by at least one flexible portion, which has a flexible portion internal surface and a flexible portion external surface, and a plurality of joint cover portions. Each joint cover portion extends from the core portion external surface of the core portion to provide a protective cover for the flexible portion external surface of at least one flexible portion of the core portion and is pivotably connected to a least one joint shield portion. The or each joint shield portion is configured to provide a protective shield for at least one flexible portion of the core portion. The core portion and the or each joint shield portion are formed as a single unitary component. A gas turbine engine that includes at least one of such gimbal, and a method of manufacturing such a gimbal are also described.