Gas Turbine Vane Arrangement Load Transmission
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Solution Overview
Problem
Conventional fan outlet guide vanes in gas turbine engines face challenges in efficiently transmitting torsional, axial, and radial loads without additional structural support, leading to weight and cost penalties, and potential weld quality issues.
Innovation Solution
A method of manufacturing a vane arrangement involving an aerofoil with a hollow cavity and a support member with a through hole, where the aerofoil is welded to the support member using a tool that prevents weld splatter and allows for increased wall thickness and radius, enabling effective load transmission with minimal weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional structural support (A-frames) is provided for load transmission, then the ability to transmit torsional loads is improved, but the weight and device complexity increase
Solution Approach 1:
The patent merges the load-bearing function with the vane structure itself by providing increased wall thickness and radius in the vane, eliminating the need for separate A-frame structures. This integration allows the vane to transmit torsional, axial, and radial loads directly through its enhanced geometry, reducing overall weight while maintaining strength.
Solution Approach 2:
The patent applies local quality by providing increased wall thickness and radius specifically in regions of the vane where load transmission is critical, rather than uniformly thickening the entire structure. This targeted approach optimizes strength where needed while minimizing unnecessary weight addition.
2Strength
If additional structural support (A-frames) is provided for load transmission, then the ability to transmit torsional loads is improved, but the device complexity and cost increase
Solution Approach 1:
The patent combines the load-bearing function with the vane structure itself, eliminating the need for separate A-frame components. This integration simplifies the overall device by reducing the number of parts while maintaining the ability to transmit torsional, axial, and radial loads through the enhanced vane geometry.
3Ease of manufacture
If welding is performed without a protective tool, then the manufacturing process is simpler, but weld splatter contaminates the cavity surface reducing weld quality
Solution Approach 1:
The patent introduces a protective tool as an intermediary element during the welding process. This tool prevents weld splatter from contaminating the cavity surface, ensuring high weld quality. The tool is positioned to protect critical surfaces while allowing the welding operation to proceed, and can be removed after welding completes.
4Strength
If wall thickness is increased to improve load transmission, then the strength is improved, but the weight increases
Solution Approach 1:
The patent applies local quality by providing increased wall thickness and radius specifically in regions of the vane where load transmission is critical, rather than uniformly thickening the entire structure. This targeted approach optimizes strength where needed while minimizing unnecessary weight addition.
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 method enhances the ability to transmit loads while minimizing weight and cost, improving weld quality and reducing the risk of stress-raising features, thus enhancing the structural integrity and efficiency of the vane arrangement.
Implementation Method 1
welding the aerofoil to the stub
Data Source
AI summary
A method of manufacturing a vane arrangement for a gas turbine engine comprises providing an aerofoil having a hollow cavity with an open end and providing a support member having a stub with a through hole extending therethrough. The method comprises welding the aerofoil to the stub such that the open end of the hollow cavity of the aerofoil is aligned with the through hole of the stub so as to define a hollow region extending through the support member and stub to the cavity of the aerofoil. During welding a tool is positioned within the through hole and cavity and is aligned with an interface between the stub and aerofoil, the tool being configured to prevent weld splatter onto a surface of the cavity or through hole.