Wireless Balancing System for Gas Turbine Rotor Assemblies
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Solution Overview
Problem
Manual balancing of rotor assemblies in gas turbine engines is time-consuming, requires experienced technicians, and results in increased fuel consumption and environmental emissions due to repeated engine cycling.
Innovation Solution
A wireless balancing system comprising vibration sensors, a controller assembly, and a balancing assembly that modifies weight distribution automatically to correct imbalances, allowing for continuous operation without stopping the engine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual balancing is performed by coupling weights and cycling the engine through its full rotor operating range, then vibration levels can be reduced to acceptable levels, but the process becomes time-consuming and requires multiple engine startups and shutdowns
Solution Approach 1:
The balancing assembly automatically adjusts its own weight distribution based on real-time vibration feedback from sensors, eliminating the need for manual intervention and repeated engine cycling. The system self-regulates by rotating balancing members to optimal positions based on measured vibration amplitudes and phases.
Solution Approach 2:
Vibration sensors continuously monitor the rotor assembly and provide real-time data to the control system. The control system processes this feedback and automatically adjusts the balancing assembly's weight distribution, creating a closed-loop control system that rapidly converges to optimal balancing without requiring multiple engine cycles.
2Reliability
If manual balancing requires experienced technicians to perform multiple balancing iterations, then acceptable vibration levels can be achieved, but labor costs and complexity increase
Solution Approach 1:
The patent replaces manual mechanical balancing operations with an automated electronic control system. The control system uses sensors, processors, and automated actuators to perform balancing functions that previously required skilled technicians to manually add weights and interpret vibration data, thereby reducing both labor requirements and procedural complexity.
Solution Approach 2:
The balancing system automatically determines the optimal weight distribution and positions without human intervention. The control system processes vibration data, calculates required corrections, and actuates the balancing members autonomously, eliminating the need for experienced technicians and simplifying the overall procedure.
3Reliability
If the engine is cycled repeatedly during manual balancing, then corrective weights can be optimized, but fuel consumption and CO2 emissions increase
Solution Approach 1:
The balancing process occurs continuously during engine operation without requiring shutdowns or repeated cycling. The system maintains engine running state throughout the balancing procedure, allowing real-time measurement and correction of imbalances, thereby eliminating the fuel consumption and emissions associated with multiple engine startups and shutdowns.
Solution Approach 2:
Real-time vibration feedback enables the system to determine optimal balancing corrections during continuous operation. The control system uses ongoing vibration measurements to iteratively adjust the balancing assembly while the engine remains running, achieving optimal balance without the energy-intensive repeated cycling required by manual methods.
4Extent of automation
If wireless communication is implemented between the balancing assembly and controller, then automated balancing can be achieved, but device complexity increases
Solution Approach 1:
Wireless communication acts as an intermediary between the balancing assembly and controller, enabling automated operation without requiring complex physical wiring connections. The wireless interface transmits control commands and sensor data through electromagnetic signals, simplifying the physical system architecture while maintaining full automation capability.
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 quick, automated balancing of rotor assemblies, reducing vibration levels, minimizing fuel and labor costs, and decreasing CO2 emissions by eliminating the need for multiple engine startups and shutdowns.
Implementation Method 1
a plurality of vibration sensors positioned to sense vibrations of the rotatable member
Implementation Method 2
the rotating shaft or disk rotates about its axis and generates a centrifugal force that is substantially distributed to the bearings and support structure
Data Source
AI summary
A balancing system and method for reducing imbalance in a rotatable member of a machine is provided. The system includes a plurality of vibration sensors positioned about a stationary portion of the machine, a controller assembly communitively coupled to the plurality of vibration sensors, and a balancing assembly coupled to the rotatable member, said balancing assembly configured to wirelessly communicate with said controller assembly, said balancing assembly configured to modify the weight distribution of the rotatable member in response to a command wirelessly transmitted from the controller assembly. The controller assembly is configured to receive data from the plurality of vibration sensors and determine an imbalance in the rotatable member using the received data.