Vane Ring Airflow Correction Using 3D Scan-Guided Deformation
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Solution Overview
Problem
Existing methods for producing and assembling vane rings in gas turbine engines are inefficient and prone to costly failures due to blind deformation attempts, leading to potential damage and time-consuming rework, especially when identifying and correcting airflow discrepancies in individual vanes.
Innovation Solution
A process involving 3D digital modeling, computerized airflow simulation, and targeted plastic deformation of specific vanes based on simulation results to correct airflow discrepancies, reducing the likelihood of damage and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If blind deformation attempts are made to correct airflow discrepancies, then production speed is maintained, but manufacturing precision deteriorates due to potential damage and costly failures
Solution Approach 1:
The patent applies preliminary action by performing computerized airflow simulations before physical deformation operations. The system creates a digital twin of the vane ring, simulates airflow patterns, identifies discrepancies, and determines the exact deformation needed for each vane. This virtual preparation guides subsequent physical deformation operations, preventing blind attempts and reducing damage while maintaining production efficiency.
2Manufacturing precision
If traditional inspection methods are used to identify airflow discrepancies, then manufacturing precision is maintained, but productivity deteriorates due to time-consuming rework
Solution Approach 1:
The patent creates a digital copy (digital twin) of the physical vane ring geometry through 3D scanning. This virtual replica is then used for computerized airflow simulations to identify discrepancies without requiring physical trial-and-error or time-consuming rework. The digital model allows rapid iteration and optimization, significantly reducing production time while maintaining high precision in flow discrepancy detection.
Solution Approach 2:
The patent replaces traditional mechanical inspection methods with computerized airflow simulations. Instead of physically testing each vane or using time-consuming manual inspection, the system uses computational fluid dynamics (CFD) to simulate airflow patterns and identify discrepancies. This substitution dramatically reduces inspection time while maintaining or improving detection accuracy.
3Manufacturing precision
If comprehensive airflow testing is performed on all vanes, then manufacturing precision is improved, but loss of time increases due to extensive inspection requirements
Solution Approach 1:
The patent segments the comprehensive airflow testing process into two parts: (1) virtual simulation-based identification of problematic vanes, and (2) targeted physical inspection only of vanes flagged by the simulation. This segmentation allows the system to maintain high manufacturing precision by thoroughly analyzing airflow compliance while reducing inspection time by avoiding unnecessary physical testing of all vanes, focusing only on those identified as problematic by the digital twin simulation.
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
Enhances the precision and speed of vane ring production by identifying and correcting airflow issues in individual vanes, thereby reducing scrap rates and production time while ensuring compliance with specifications.
Implementation Method 1
creating a tri-dimensional digital model of the vane ring in an initial configuration, the creating including scanning the vane ring in the initial configuration
Implementation Method 2
using the tri-dimensional digital model, performing a computerized simulation of airflow across the vane ring in the initial configuration
Implementation Method 3
plastically deforming at least one vane of the pair of adjacent vanes
Data Source
AI summary
The process can include: scanning the vane ring, including creating a tri-dimensional digital model of the vane ring in an initial configuration; performing a computerized simulation of airflow across the vane ring based on the tri-dimensional digital model; identifying one or more flow discrepancy based on the computerized airflow simulation; associating a subset of one or more vanes of the set of vanes to the one or more flow discrepancy; and plastically deforming at least one vane of the subset.