Variable Stator Vane Bushing Removal with Lead Screw Puller
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Solution Overview
Problem
The existing methods for removing bushings from variable stator vanes in gas turbines are time-consuming and costly, requiring disassembly of the rotor and use of cranes, due to operational wear and the need for replacement.
Innovation Solution
A tool and method utilizing a cylindrical housing, lead screw, threaded nut, and pulling module with puller arms to engage and remove bushings without disassembling the rotor, allowing for radial outward positioning and rotation of the lead screw to adjust the position of the threaded nut and pulling module until the bushing is removed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods are used to remove bushings, then complete removal is achieved, but disassembly of rotor and use of crane is required, increasing time and cost
Solution Approach 1:
A specialized removal tool acts as an intermediary device between the bushing and the operator. The tool includes a pulling mechanism with jaws that engage the bushing, a lead screw for applying controlled pulling force, and a housing that positions the mechanism radially outward from the bushing. This intermediary tool enables bushing removal without requiring disassembly of the rotor or use of heavy crane equipment.
Solution Approach 2:
The removal tool is divided into functional segments: a housing that positions radially outward, a lead screw mechanism for force application, and a pulling module with jaws that engage the bushing. This segmentation allows each component to perform its specific function independently, enabling the overall goal of bushing removal without rotor disassembly.
2Ease of repair
If traditional methods are used to remove bushings, then bushing replacement is achieved, but rotor disassembly and crane use are required, increasing costs
Solution Approach 1:
The removal tool serves as an intermediary that simplifies the repair process. By providing a dedicated mechanism with engagement jaws that grip the bushing and a lead screw that applies controlled pulling force, the tool makes bushing replacement straightforward without requiring complex disassembly procedures or heavy equipment.
Solution Approach 2:
The bushing is extracted from its installed position using the pulling mechanism. The jaws engage the bushing directly, and the lead screw mechanism extracts it radially outward from the compressor casing, separating the bushing removal operation from the need to disassemble the rotor or other major components.
3Ease of repair
If access to interior of casing is required for bushing removal, then bushing replacement is possible, but disassembly and crane use are required
Solution Approach 1:
The removal tool approaches the bushing from a radial dimension rather than requiring axial access into the compressor casing interior. The housing positions radially outward from the bushing, and the pulling force is applied in the radial direction, allowing bushing removal through the casing wall without requiring disassembly of internal components or use of crane equipment.
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
Enables efficient and cost-effective removal of bushings without the need for crane-assisted rotor disassembly, reducing maintenance time and costs by allowing for bushing replacement without dismantling the casing or removing the rotor.
Implementation Method 1
a lead screw, a threaded nut, and a pulling module with puller arms to engage the bushing. The lead screw is rotatably secured within the cylindrical housing by a threaded nut engaged with the lead screw
Data Source
AI summary
A tool for removal of a bushing (such as a bushing of a variable stator vane assembly of a compressor) is provided. The tool includes a cylindrical housing, a lead screw, a threaded nut, and a pulling module with puller arms to engage the bushing. The housing defines a longitudinal axis along which the lead screw extends. The lead screw is rotatably secured within the cylindrical housing by a threaded nut engaged with the lead screw. The pulling module is removably attached to the threaded nut, such that the lead screw passes through the threaded nut before passing through the pulling module. The pulling module is provided with a pair of oppositely disposed puller arms, and each puller arm is provided with a hook portion having an engagement tab configured to engage a respective notch on the bushing. A method of removing the bushing using the tool is also disclosed.