Abstract:
A transport system suited for transporting a turbine engine mounted to an engine docking unit is provided. The transport system is capable of adjusting the attitude of the docking unit in at least the lateral and longitudinal directions relative to the engine to facilitate the loading and unloading of the turbine engine to and from the transport system.

Description:
TECHNICAL FIELD 
       [0001]    The invention relates generally to a transport system for transporting and manipulating a gas turbine engine. 
       BACKGROUND OF THE ART 
       [0002]    An aero gas turbine engine is typically transported to a test cell using an overhead trolley system which requires strict safety procedures to be followed during its operation and particularly during the transfer of the engine from the build stand to the overhead trolley system. The operator of the overhead trolley system must also exercise extreme care while transporting and manually manipulating the turbine engine so as not to damage any parts of the engine while, for example, docking the engine to the test cell. Such overhead trolley systems require relatively large assembly/testing plants and greatly limit any floor layout reconfiguration of the engine assembly/testing plants. 
         [0003]    Floor mobile systems have also been used in the past for transporting engines, but they generally have large footprints and still require other intermediate transition systems to handle the engines from the build stand to the docking system and to connect the docking system to the test bench. The transfer of the engine from the floor mobile system to such intermediate transition systems results in extra manipulation steps and, thus, increases the likelihood of the engine being damaged. 
         [0004]    There is thus a need for a new transport system which offers a better control of the load transfer process of the gas turbine engine to and from the transport system and which facilitates and minimize the engine manipulations. 
       SUMMARY 
       [0005]    Accordingly, it is an object of the present invention to provide a gas turbine engine transport system. 
         [0006]    According to one broad aspect there is provided a transport system for transporting a gas turbine engine comprising: a support frame movably supported on a floor surface by at least one floor engaging member; a support member articulated to the support frame, the support member having a mounting portion for releasable engagement with a counterpart mounting portion provided on the gas turbine engine; at least a first actuator operatively connected between the support frame and the support member for causing the support member to rotate about a first axis; at least a second actuator operatively connected between the support frame and the support member for causing the support member to rotate about a second axis; and a load monitoring unit for measuring and providing feedbacks on reaction forces on the support member. 
         [0007]    According to another aspect, there is provided a transport system for transporting a turbine engine mounted to an engine docking unit, the transport system comprising: a movable support frame supported on a floor surface by at least one floor engaging member; a support member pivotally connected to the support frame in an upright position wherein the support member is pivotable from the upright position about a first axis and a second axis; an upper portion of the support member having one of a male mounting portion and a female mounting portion mating to a counterpart mounting portion on the engine docking unit, the male and female mounting portions cooperating to prevent angular movements of the engine docking unit relative to the support member while allowing free axial disengagement of the engine docking unit from the support member in an upward direction; and means for pivoting said support member about at least said first and second axes. 
         [0008]    According to a further aspect, there is provided a method for transferring a gas turbine engine from a carrying structure to which the gas turbine engine is mounted to a receiving structure, wherein one of the carrying structure and the receiving structure is secured to a support member articulated to a support frame which is movably supported on a floor surface, the method comprising the steps of: 
         [0009]    a) actuating the support member so as to position the receiving structure and the carrying structure in a relative position suitable for fastening the gas turbine engine to the receiving structure; 
         [0010]    b) fastening the gas turbine engine to the receiving structure; 
         [0011]    c) actuating the support member while simultaneously monitoring a magnitude and direction of a reaction force on the support member until the magnitude and direction of the reaction force indicates that the gas turbine engine is entirely supported by the receiving structure; and 
         [0012]    d) unfastening the gas turbine engine from the carrying structure. 
         [0013]    Further details of these and other aspects of the present invention will be apparent from the detailed description and figures included below. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0014]    Reference is now made to the accompanying figures, in which: 
           [0015]      FIG. 1  is a schematic axial cross-section of a gas turbine engine; 
           [0016]      FIG. 2  is an isometric view showing a transport system for transporting a gas turbine engine according to one embodiment of the present invention; 
           [0017]      FIG. 3  is a top plan view of the transport system of  FIG. 2 ; 
           [0018]      FIG. 4  is a front elevation view of the transport system of  FIG. 2 ; 
           [0019]      FIG. 5  is a side elevation view of the transport system of  FIG. 2 ; 
           [0020]      FIG. 6  is an isometric detailed view of the transport system of  FIG. 2  showing the directions of movement of various actuators and of a support member. 
           [0021]      FIG. 7  is a partial cross-sectional side view of the transport system of  FIG. 2  along line  7 - 7  of  FIG. 3  showing details of the support member connected to a gimbal joint, a pneumatic actuator and an actuator assembly. 
           [0022]      FIG. 8  is a cross-sectional front view of the transport system of  FIG. 2  along line  8 - 8  of  FIG. 3  showing details of the support member to the gimbal joint, the pneumatic actuator and another actuator assembly. 
           [0023]      FIG. 9  is a partial cross-sectional view of the transport system of  FIG. 2  along line  9 - 9  of  FIG. 8  showing details of a movable support member casing. 
           [0024]      FIG. 10  is a partial cross-sectional view of the transport system of  FIG. 2  along line  10 - 10  of  FIG. 3  showing details of a floor engaging member comprising ball casters. 
           [0025]      FIG. 11  is an isometric view of the actuator assembly shown in  FIG. 7 . 
           [0026]      FIG. 12  is an axial cross-sectional view of the actuator assembly of  FIG. 11  along line  12 - 12  of  FIG. 11 . 
           [0027]      FIG. 13  is an isometric view showing a transport system for transporting a turbine engine comprising a bearing plate, according to another embodiment of the present invention. 
           [0028]      FIG. 14  is a top plan view of the transport system of  FIG. 13 . 
           [0029]      FIG. 15  is a cross-sectional front view of the transport system of  FIG. 13  along line  15 - 15  of  FIG. 14  showing details of the support member connected to a gimbal joint, a pneumatic actuator and a manual actuator assembly. 
           [0030]      FIG. 16  is a side elevation view of the manual actuator assembly shown in  FIG. 15 . 
           [0031]      FIG. 17  is an axial cross-sectional view of the manual actuator assembly of  FIG. 16  along line  17 - 17  of  FIG. 16 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0032]      FIG. 1  illustrates a gas turbine engine  10  of a type preferably provided for use in subsonic flight, generally comprising in serial flow communication a fan  12  through which ambient air is propelled, a multistage compressor  14  for pressurizing the air, a combustor  16  in which the compressed air is mixed with fuel and ignited for generating an annular stream of hot combustion gases, and a turbine section  18  for extracting energy from the combustion gases. It will be understood however that the invention is equally applicable to other types of gas turbine engines such as a turbo-shaft, a turbo-prop, or auxiliary power units. 
         [0033]      FIG. 2  shows a transport system, shown generally at  20 , that is used for transporting the gas turbine engine  10  to and from a build stand, a test cell or a shipping post for example, located within or proximal to a production facility. The transport system  20  is adapted to transport the engine  10  while the gas turbine engine  10  is mounted to an engine docking unit (not shown). The engine docking unit may comprise pre-dressing equipment and accessories for coupling to the gas turbine engine  10  that are required for testing and evaluation of the gas turbine engine  10 . Accordingly, the gas turbine engine  10  may be brought to the text cell in a “pre-dressed” condition in order to minimize the down time of the test cell. 
         [0034]    The transport system  20  comprises a movable support frame  22  having floor engaging members  24 . An actuated support member  26  is pivotally connected to the support frame  22  in an upright position via a gimbal joint  28  and a pneumatic actuator  30 . The actuated support member  26  is also movable connected to the support frame  22  via two actuator assemblies  32 . The transport system  20  also comprises a conventional on-board hydraulic and pneumatic system which is partially shown in  FIG. 6  and is used to power the various actuators on the transport system  20 . 
         [0035]    An upper portion of the support member  26  comprises a male mounting surface  34  which is adapted to mate to a counterpart mounting surface on the engine docking unit and is used to removably secure the engine docking unit to the transport system  20  in a single action. The male mounting comprises a cylindrical portion  36  and a tapered portion  38 . The tapered portion  38  has an upper circular cross-section  40  and a lower square cross-section  42 . The lower square cross-section  42  of the tapered portion  38  serves as preventing rotation of the engine docking unit relative to the support member  26 , and, therefore any non-circular cross-section such as oval or polygonal could also be used. An abutment  27  is provided on the surface of the square cross-section portion  42  for supporting the docking unit against gravity. The top surface of the support member  26  could also offer an arresting or seating surface on which the end wall of the socket of the engine docking unit could rest. However, in the present embodiment, the top surface of the support member  26  is occupied by a reflector (not shown). The reflector is used to trigger a laser sensor (not shown) on the test cell side. The sensor is for fool proofing the installation process. The docking unit can be readily disengaged from the support member  26  in a single operation by axially displacing the docking unit in an upward direction. 
         [0036]    The transport system  20  also comprises brackets  44  affixed to each floor engaging member  24  to improve the safety when moving the equipment with a motorized lift truck. These lift trucks typically have narrow sliding forks, which if not properly secured could slide inboard and allow the transport unit to tip off the forks. The brackets  44  increase the width of the lifting surfaces to prevent this possibility. When using a manual pallet lifter this cannot occur, the fork being non-sliding/non adjustable. It is noted that the transport system  20  can be inserted with a pallet truck on all four sides of the base. This is very convenient in small floor space area and sides, for moving engines fitted with intake and exhaust ducts. As shown in  FIG. 2 , lateral openings  45  are defined in the outboard side of the floor engaging members  24  for receiving the forks of the lift truck, the pallet lifter or the like, thereby allowing the transport system  20  to be laterally engaged. Similar openings are provided at the rear of the base of the transport system  20 . 
         [0037]    The transport system  20  also has a handle  46  affixed to the support frame  22  that can be used for maneuvering the transport system  20  during taxiing. A shelf  48  and storage boxes  50  for storing fasteners, spare components, sensors or the like associated with the testing or operation of the gas turbine engine  10  are also provided. 
         [0038]    The transport system  20  further includes an electrical control box  52  which is used to house a power supply such as a battery (not shown) and various control circuits such as a conventional programmable logic controller (PLC) (not shown) that are associated with the control and operation of the hydraulic and pneumatic system and the various actuators incorporated in the transport system  20 . A touch screen user interface  54  is also provided to interface with the PLC and facilitate the operation of the transport system  20 . 
         [0039]    In reference to  FIGS. 2-6 , levelling feet  56  are provided on the floor engaging members  24  of the transport system  20 . The levelling feet  56  are used to move the transport system  20  up and down in the P direction as shown in  FIG. 6  when the transport system  20  is stationary. The levelling feet  56  are powered by the on-board hydraulic system.  FIG. 3  shows the layout of the levelling feet  56  in relation to the floor engaging members  24 . 
         [0040]      FIG. 3  also shows the configuration of the two actuator assemblies  32  that are pivotally connected to the support member  26  and are used to cause rotation of the support member  26  about the gimbal joint  28 .  FIG. 4  shows the actuator assembly  32  that is used to push and pull the support member  26  along an X axis as shown in  FIG. 6 . This produces a rotational movement of the support member  26  from the upright position about a Y axis as show by the arrow RX in  FIGS. 4 and 6 .  FIG. 5  shows the actuator assembly  32  that is used to push and pull the support member  26  along the Y axis as shown in  FIG. 6 . This produces a rotational movement of the support member  26  from the upright position about the X axis as shown by the arrow RY in  FIGS. 5 and 6 . 
         [0041]      FIG. 7  is a partial cross-sectional view along line  7 - 7  of  FIG. 3  and shows details of the support member  26  connected to the gimbal joint  28  and the pneumatic actuator  30 . The gimbal joint  28  comprises a gimbal  58  and a trunnion  60 . A lower portion of the support member  26  is pivotally connected to the gimbal  58  at pivot point  62  to permit rotation of the support member  26  about the X axis RY. The gimbal  58  is in turn pivotally connected to the trunnion  60  to permit rotation of the support member  26  about the Y axis RX. The trunnion  60  is affixed to a casing  64  which is movable along the Z axis within the support frame  22 . The pneumatic actuator  30  is connected between a bottom side of the casing  64  and the support frame  22  at anchor point  66 . The pneumatic actuator  30  provides support for the casing  64  together with the support member  26  and also causes the casing  64  and the support member  26  to translate upwardly and downwardly along the Z axis. As shown in  FIGS. 8 and 9 , parallel rails  70  are provided on each side of the casing  64  to guide the motion of the casing  64  along the Z axis. The rails  70  have a C-shape profile and are adapted to receive and move against bearing members  72  which are affixed to the support frame. A load cell  74  is also connected in series within the load string of the pneumatic actuator  30  and is used to measure a reaction force on the support member  26  along the Z axis. 
         [0042]    Advantageously, the pneumatic actuator  30  also provides a pneumatic suspension for the support member  26  and dampens any transportation shocks. The pneumatic actuator  30  further provides resilience for engaging the engine docking unit to static structures such as a test cell. 
         [0043]      FIG. 10  shows a cross-sectional view of one of the floor engaging members  24  and shows ball casters  76 . Two ball casters  76  are provided at opposed end portions of each floor engaging member  24  and can be used to taxi the transport system  20  along relatively smooth floor surfaces. The ball casters  76  allow easy movement in all directions with equal resistance. Alternatively, the ball casters  76  can also ride within a guide rail (not shown) provided in a test cell for example and allow more precise positional adjustments of the transport system  20 . 
         [0044]      FIGS. 11 and 12  show details of one of the two actuator assemblies  32  that are used to cause the support member  26  to rotate about the X and Y axes. Each actuator assembly  32  comprises an actuator such as a hydraulic cylinder  78  and a load cell  74  that are housed within housing  80 . The housing  80  is affixed to the support frame  22 . The hydraulic cylinder  78  is operatively connected between the housing  80  and the support member  26 . The hydraulic cylinder  78  is connected to the housing via a spherical bearing  82  and to the support member  26  via a rod end bearing  84 . The load cell  74  is connected in series within the load string of the hydraulic cylinder  78  and is used to measure the reaction force on the support member  26 . 
         [0045]      FIGS. 13-15  show a transport system  20  according to another embodiment; in this embodiment the two floor engaging members  24  additionally comprise a bearing plate  86 . The bearing plate  86  is rotatably attached to the floor engaging members  24 . In this embodiment the floor engaging members  24  have ball casters  76  that are in contact with the inside surface of the bearing plate  86 . The inside surface of the bearing plate  86  provides a relatively smooth surface for the ball casters  76  on which to ride. The ball casters  76  allow the entire support frame  22  to be moved and rotated within a limited range relative to the bearing plate  86 . The bearing plate  86  is especially useful when the surface on which the transport system  20  is placed is relatively rough and minor positional adjustments are necessary. 
         [0046]    The embodiment shown in  FIGS. 13-15  also comprises manual actuator assemblies  88  instead of the hydraulic actuator assemblies  32 . The manual actuator assemblies  88  are shown in details in  FIGS. 16 and 17 . Each manual actuator assembly  88  comprises a stationary housing portion  90  that is affixed to the support frame  22 , a rotatable housing portion  92 , a load string  94  and a load cell  74 . The rotatable housing portion  92  is threadingly engaged to the stationary housing portion  90  at a threaded interface  96  to form a screw-type linear actuator. The load string  94  is connected between the rotatable housing portion  92  and the support member  26 . The load string  94  is rotatably connected to the rotatable housing portion  92  and is connected to the support member  26  via the rod end bearing  84 . The load cell  74  is connected in series within the load string  94  of and is used to measure the reaction force on the support member  26 . 
         [0047]    The rotatable housing portion  92  comprises a square socket  98  to which a ratchet  100  having a square drive can be coupled. The ratchet  100  can be used to turn the rotatable housing portion  92  relative to the stationary housing portion  90 . Due to the threaded interface between the rotatable housing portion  92  and the stationary housing portion  90 , the relative rotation causes the rotatable housing portion  92  to either move away or towards the stationary housing portion  90  depending on the direction of rotation. This in turn causes the load string  94  to either push or pull the support member  26 . 
         [0048]    During operation, the transport system  20  may be used to transport the gas turbine engine  10  mounted to an engine docking unit from a build stand where gas turbine engine  10  is assembled for example, to a testing facility for a pass-off test prior to shipping the gas turbine engine  10  to a customer. The engine docking unit may comprise pre-dressing equipment and accessories for coupling to the gas turbine engine  10  that are required for testing and evaluation of the gas turbine engine  10 . Accordingly, the engine docking system may be used to interface the gas turbine engine  10  directly to the test cell. The engine docking unit may also comprise engine mounts to which the gas turbine engine  10  is to be secured. 
         [0049]    The transport system  20  greatly facilitates the task of transferring the gas turbine engine  10  from the build stand to the engine docking unit. The actuated support member  26  of the transport system  20  allows the engine docking unit to be precisely brought in proximity to the gas turbine engine  10  on the build stand and align the various pre-dressing equipment and engine mounts to their counterparts on the gas turbine engine  10 . At this point, an operator can simply and safely make all the necessary connections between the gas turbine engine  10  and the engine docking unit. Once the gas turbine engine  10  has been secured to the engine docking unit, the gas turbine engine  10  can safely be unfastened from the build stand. 
         [0050]    The transport system  20  can then be taxied to the testing facility using a floor transport system such as a pallet lifter or using the ball casters  76 . At the testing facility, actuated support member  26  allows the engine docking unit together with the gas turbine engine  10  to be precisely manipulated so as to allow the engine docking unit to be docked to the testing cell together with the engine. Once the engine docking unit has been securely docked to the testing facility, either the transport system  20  can be lowered or the engine docking unit can be raised so as to disengage the engine docking unit from the transport system  20  in a single action. 
         [0051]    The PLC is adapted to control the hydraulic and pneumatic actuators on the transport system  20  via the touch screen user interface  52 . The various load cells  74  are also interfaced to the PLC to inform the operator of the reaction forces on the support member  26  so that the operator can avoid actuating the support member  26  in an unsafe manner. For example, when the hydraulic actuator assemblies  32  are used, it is possible to provide means of limiting the applied forces so as to prevent accidental overloading of turbine engine components during engine transfers. It is also possible for example to verify during engine transfer that the weight of the gas turbine engine  10  is entirely supported by the receiving structure such as the test cell before safely unfastening the gas turbine engine  10  from the transport system  20 . By monitoring the reaction loads on the support member  26  through the use of the load cells and the PLC, the support member  26  can be actuated to release the load at the attachment points, to thereby permit safe transfer from and to the transport system. A load monitoring system as provided by the load cells and the PLC or any other suitable load monitoring elements allows the operator to know the magnitude or direction of the loads at the connection points and, thus, provide guidance as to how the actuator must be operated in order to permit the transfer of the engine. For instance, the engine is typically connected to a build stand with two side mounts. These mounts can be provided in the form of a lug and yoke arrangement connected with quick release pins. To enable the pins removal, during the engine transfer process, the shear loads must be removed from the pins. The same applies in the transfer from the transport system to the engine testing stand, and shipping undressing posts. 
         [0052]    It is apparent that conventional position sensors such as encoders can readily be integrated into the transport system  20  so as to provide feedback of the angular position of the support member  26  or spatial coordinates of the tip of the support member  26 . A typical movement envelope of the tip of the support member  26  would be about ±50 mm (2 inches) along the X axis, +0 to −330 mm (+0 to −13 inches) along the Y axis, from the upright position, and, about ±50 mm (2 inches) along the Z axis. The Y axis being in a rearward direction as shown in  FIG. 6 . Evidently, the transport system  20  could also be adapted to enable other suitable ranges of motion depending on the application. 
         [0053]    It is also apparent that the male mounting surface  34  on the support member  26  could be replaced instead by a female mounting surface adapted to mount to a counterpart male mounting surface on the engine docking unit. Alternatively, the support member  26  could have two male mounting surfaces arranged in a fork configuration that could be used instead of a tapered portion  38  of varying cross section. The fork configuration would prevent relative rotation of the engine docking unit relative to the support member  26 . It is clear that such arrangements would evidently produce the same “single action” securing arrangement of the present configuration. 
         [0054]    Further, the engine docking unit that is used to mount the gas engine turbine  10  may be any type of framework that is suitable to structurally interface the engine to the movable support frame  22 . The examples described above comprises engine pre-dressing equipment but simpler configurations would also work. 
         [0055]    The gimbal joint  28  provides pivotal movement of the support member  26  in multiple directions. Accordingly other types of joints providing pivotal movement of the support member  26  about at least two axes could also be used such as for example two separate pivot joints, a ball joint or a universal joint and would be within the scope of the present invention. 
         [0056]    The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without department from the scope of the invention disclosed. It is apparent that the transport system described above can be fabricated using conventional manufacturing procedures using suitable materials such as a structural grade steel or any combinations of suitable materials that would be apparent to a person skilled in the relevant art. It is also apparent that this transport system could also be used to transport and manipulate larger engine parts for the purpose of docking and undocking these parts to an engine core casing in a horizontal engine assembly line and/or a test cell environment. Still other modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims.