V-Shaped Compressor Drive Shaft Coupling for Geared Turbine Assembly
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Solution Overview
Problem
The existing connection methods between the gearbox input drive shaft and the intermediate pressure compressor drive shaft in geared gas turbine engines require complex machining and multiple aperture sets, leading to structural weakening and assembly challenges due to the use of taper bolts and conventional bolts, which complicates the inter-engagement of splines and increases the risk of damage.
Innovation Solution
A V-shaped cross-section intermediate pressure compressor drive shaft with removably connected limbs using bolted joints, curvic couplings, and Hirth couplings, allowing for secure connections without the need for taper bolts, simplifying assembly and enhancing structural integrity by eliminating the need for multiple aperture sets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If taper bolts and conventional bolts are used to connect the gearbox input drive shaft and intermediate pressure compressor drive shaft, then the connection is secure, but the structure becomes complex with multiple aperture sets leading to structural weakening and assembly challenges
Solution Approach 1:
The patent combines the functions of multiple connection methods (taper bolts and conventional bolts) into a single curvic coupling structure. This single structure provides both the secure connection and alignment functions that previously required separate components and multiple aperture sets, thereby reducing structural complexity while maintaining connection strength.
Solution Approach 2:
The curvic coupling structure serves multiple functions simultaneously: it provides secure mechanical connection, enables precise alignment between shafts, and facilitates easy assembly and disassembly. This multi-functional design eliminates the need for separate taper bolts and conventional bolts, reducing the number of aperture sets required and simplifying the overall connection structure.
2Reliability
If multiple aperture sets are used for connection, then secure attachment is achieved, but structural strength is weakened and assembly becomes more challenging
Solution Approach 1:
The curvic coupling integrates multiple attachment functions into a single unified structure with interlocking teeth. This eliminates the need for multiple separate aperture sets and fasteners, maintaining secure attachment reliability while preserving the structural integrity of the drive shaft by reducing the number of holes required.
3Manufacturing precision
If taper bolts are used for connection, then alignment is achieved, but the inter-engagement of splines becomes complex and increases the risk of damage
Solution Approach 1:
The curvic coupling structure performs both alignment and spline inter-engagement functions within a single integrated design. The tapered surfaces of the curvic teeth provide automatic alignment during assembly, while the interlocking teeth geometry guides and protects the spline engagement, eliminating the complexity and damage risk associated with separate taper bolt and spline alignment procedures.
4Reliability
If complex connection methods are used, then secure attachment is achieved, but assembly and disassembly processes become time-consuming and costly
Solution Approach 1:
The curvic coupling provides secure, reliable attachment through its interlocking tooth geometry while enabling rapid assembly and disassembly. The tapered surfaces allow for self-alignment and easy engagement, and the modular design facilitates quick release, significantly improving assembly efficiency compared to complex multi-component connection methods without compromising connection reliability.
Data Source
AI summary
A gas turbine engine comprising a fan, an intermediate pressure compressor, a high pressure compressor, a high pressure turbine, a low pressure turbine and a gearbox. The low pressure turbine is arranged to drive the intermediate pressure compressor via a shaft and an intermediate pressure compressor drive shaft and the fan via the shaft, a gearbox input shaft, the gearbox and a gearbox output shaft. The intermediate pressure compressor drive shaft has a V-shaped cross-section comprising a base, a first limb and a second limb extending from the base. An end of the first limb of the intermediate pressure compressor drive shaft is removably connected to the intermediate pressure compressor. An end of the second limb of the intermediate pressure compressor drive shaft is removably connected to the gearbox input shaft and the base of the intermediate pressure compressor drive shaft is removably connected to the shaft.