Unitized Compressor Vane Casing for Gas Turbine Leakage Control

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Solution Overview

Problem

Current compressor case and vane systems in gas turbine engines are complex, heavy, costly, and prone to leakage due to multiple interfaces, leading to operability issues and high maintenance costs.

Innovation Solution

A unitized compressor vane and casing design where vanes are integral with the case wall, eliminating the need for multi-piece constructions and reducing interfaces, achieved through casting or other manufacturing methods, resulting in a lightweight, low-leakage system with improved ovalization control and flexibility in material selection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If case-tied vane assemblies with intermediate structures are used, then outer endwall displacement control is improved, but device complexity increases

Engineering Contradiction:

Improveouter endwall displacement controlVSAvoidcomplexity of vane assembly architecture

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges the vane assembly with the compressor case into a unitized structure where vanes are directly integrated with the case wall, eliminating the need for separate intermediate structures and reducing the number of components while maintaining endwall displacement control

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If multiple seal elements and interfaces are used in case-tied designs, then outer endwall displacement control is improved, but reliability deteriorates due to multiple leak paths

Engineering Contradiction:

Improveouter endwall displacement controlVSAvoidseal integrity and leak prevention

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The unitized design merges the vane assembly with the case wall to create fewer interfaces, thereby reducing the number of potential leak paths and improving seal integrity while maintaining displacement control through the integrated structure

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If segmented vane assemblies with multiple interfaces are used, then outer endwall displacement control is improved, but manufacturing cost increases

Engineering Contradiction:

Improveouter endwall displacement controlVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent combines the vane assembly and compressor case into a single unitized structure, reducing the number of parts and interfaces, which simplifies manufacturing processes and reduces assembly costs while maintaining precise endwall displacement control

Inventive Principle:

Principle #5Merging (Combining)

4Manufacturing precision

If case-tied architecture with retaining hooks and seal interfaces is used, then outer endwall displacement control is improved, but maintenance cost increases due to wear

Engineering Contradiction:

Improveouter endwall displacement controlVSAvoidmaintenance cost

Core Design Contradiction:

Manufacturing precisionVSEase of repair

Solution Approach 1:

The unitized design eliminates retaining hooks and separate seal interfaces by integrating the vane assembly directly with the case wall, reducing wear-prone components and simplifying maintenance while maintaining displacement control through the integrated structure

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS8950069B2Integrated compressor vane casing

Publication Date: 2015.02.10 ROLLS ROYCE NORTH AMERICAN TECHNOLOGIES INC

AI summary

A low leakage, integral fixed vane system for a gas turbine engine compression system which can accommodate the latest 3-D aerodynamic airfoil geometries and provide endwall ovalization control. A unitized construction wherein the vanes are integral with the case wall in the compression system.