Patent Description:
Turbomachines, such as gas turbine engines, include various components that are typically coupled together via interface flanges and hardware. For example, in the context of a turbofan gas turbine propulsion engine, components such as the inlet, fan containment housing, front frame, forward outer bypass duct, aft outer bypass duct, and thrust reverser are typically connected using bolts that extend through openings in the mating interface flanges formed on the components, and a nut that is threaded on each of the bolts.

In many instances, each turbomachine component has multiple flanges. For example, some turbomachine components can have in the range of <NUM>-<NUM> interface flanges. As may be appreciated, a relatively large amount of time can be associated with installing <NUM>-<NUM> bolts and nuts at each interface flange. This time can then stack up across the multiple components that need to be attached.

Moreover, in the context of thrust reversers, current interface flange arrangements can limit the amount of thrust reverser clocking. For example, when adjacent components each include <NUM> interface flanges (and openings), thrust reverser clocking is limited to <NUM>-degree increments (i.e., <NUM>°/<NUM> openings). Such limitations may be undesirable for some turbofan engine configuration;.

<CIT>, <CIT>, <CIT> and <CIT> disclose examples of turbomachines components coupled with different means.

Hence, there is a need for turbomachine components and methods for coupling turbomachine components that does not require a relatively large amount of time installing fastener hardware at each mating interface flange and/or does not limit the clocking of certain components, such as thrust reverser components. The present invention addresses one or more of these needs.

In one embodiment, a turbomachine includes a first component and a second component. The first component extends about an axis of symmetry from a first component mating end to an opposing first component second end. The first component has a plurality of internal attachment flanges spaced evenly around the first component mating end, and each internal attachment flange includes a first component flange section and a mating section coupled to the first component flange section. Each first component flange section extends radially from the first component mating end and is disposed perpendicular to the axis of symmetry, and each mating section is spaced apart from the first component mating end and extends parallel to the axis of symmetry. The second component extends about the axis of symmetry from a second component mating end to an opposing second component second end. The second component is coupled to the first component and has a plurality of external attachment flanges spaced evenly around the second component mating end. Each external attachment flange includes a second component flange section and a receptacle section. Each second component flange section extends radially from the second component mating end and is disposed perpendicular to the axis of symmetry. Each receptacle section includes a first arm, a second arm, and a third arm that is connected to the first and second arms. The first and second arms of each receptacle section extend parallel to the axis of symmetry and are spaced apart from each other, and the third arm of each receptacle section extends perpendicular to the axis of symmetry, whereby each receptacle section defines a receptacle section cavity dimensioned to receive one of the mating sections. The mating section of each internal attachment flange is associated with, and is disposed within, the receptacle section cavity of a different one of the external attachment flanges, to thereby define a plurality of mating flange pairs, and a subset of the mating flange pairs each includes an anti-rotation feature, to thereby define a plurality of anti-rotation mating flange pairs.

In another embodiment, a turbomachine includes a first component and a second component. The first component extends about an axis of symmetry from a first component mating end to an opposing first component second end. The first component has a plurality of internal attachment flanges spaced evenly around the first component mating end, and each internal attachment flange includes a first component flange section and a mating section coupled to the first component flange section. Each first component flange section extends radially from the first component mating end and is disposed perpendicular to the axis of symmetry, and each mating section is spaced apart from the first component mating end and extends parallel to the axis of symmetry. The second component extends about the axis of symmetry from a second component mating end to an opposing second component second end. The second component is coupled to the first component and has a plurality of external attachment flanges spaced evenly around the second component mating end. Each external attachment flange includes a second component flange section and a receptacle section. Each second component flange section extends radially from the second component mating end and is disposed perpendicular to the axis of symmetry. Each receptacle section includes a first arm, a second arm, and a third arm that is connected to the first and second arms. The first and second arms of each receptacle section extend parallel to the axis of symmetry and are spaced apart from each other, and the third arm of each receptacle section extends perpendicular to the axis of symmetry, whereby each receptacle section defines a receptacle section cavity dimensioned to receive one of the mating sections. Each mating section is associated with, and is disposed within, the receptacle section cavity of a different one of the external attachment flanges, to thereby define a plurality of mating flange pairs. A subset of the mating flange pairs each includes an anti-rotation feature, to thereby define a plurality of anti-rotation mating flange pairs. Each anti-rotation mating flange pair has fastener hardware that extends therethrough, and the plurality of anti-rotation mating flange pairs are spaced asymmetrically about the axis of symmetry.

In yet another embodiment, a method of coupling together two turbomachine components includes providing a first component and a second component. The first component extends about an axis of symmetry from a first component mating end to an opposing first component second end. The first component has a plurality of internal attachment flanges spaced evenly around the first component mating end. Each internal attachment flange includes a first component flange section and a mating section coupled to the first component flange section. Each first component flange section extends radially from the first component mating end and is disposed perpendicular to the axis of symmetry. Each mating section is spaced apart from the first component mating end and extending parallel to the axis of symmetry, and a first subset of the internal attachment flanges each include a first anti-rotation feature. The second component extends about the axis of symmetry from a second component mating end to an opposing second component second end. The second component has a plurality of external attachment flanges spaced evenly around the second component mating end. Each external attachment flange includes a second component flange section and a receptacle section. Each second component flange section extends radially from the second component mating end and is disposed perpendicular to the axis of symmetry. Each receptacle section includes a first arm, a second arm, and a third arm that is connected to the first and second arms. The first and second arms of each receptacle section extend parallel to the axis of symmetry and are spaced apart from each other, and the third arm of each receptacle section extends perpendicular to the axis of symmetry, whereby each receptacle section defines a receptacle section cavity dimensioned to receive one of the mating sections. A second subset of the external attachment flanges each include a second anti-rotation feature. The first component mating end and the second component mating end are abutted in a manner that (i) each internal attachment flange is radially disposed between two adjacent external attachment flanges and (ii) each internal attachment flange that includes a first anti-rotation feature is radially disposed adjacent one of the external attachment flanges that includes a second anti-rotation feature, and relative rotation is provided between the first component and the second component until the mating section of each internal attachment flange is disposed within the receptacle section cavity of one of the two adjacent external attachment flanges, and such that each of the first anti-rotation features is aligned with a different one of the second anti-rotation features.

Furthermore, other desirable features and characteristics of the turbomachine and method will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the preceding background.

With reference first to <FIG>, a partial, cross-sectional view of one example of a turbomachine <NUM> is depicted. The depicted portion of the turbomachine <NUM> is illustrated as being substantially axisymmetric about a longitudinal axis <NUM>, which also comprises an axis of rotation for the turbomachine <NUM>. In the depicted embodiment, the gas turbine engine <NUM> is an annular multi-spool turbofan gas turbine jet engine and, for completeness, will be briefly described. Before doing so, however, it is noted that the more detailed descriptions of turbomachine components and coupling methods described herein are not limited to turbofan gas turbine engines, but may be applied to numerous other types of turbomachine types including, but not limited to, gas turbine engines included with auxiliary power units, turboprop, turboshaft, and turbojet engines, whether deployed onboard an aircraft, watercraft, or ground vehicle (e.g., a tank), included within industrial power generators, or utilized within another platform or application.

With the above in mind, the depicted turbomachine <NUM> includes a fan section <NUM>, a compressor section <NUM>, a combustor section <NUM>, a turbine section <NUM>, and an exhaust section <NUM>. The fan section <NUM> includes a fan <NUM> that draws air into the gas turbine engine <NUM>, via an inlet <NUM> (which may comprise a non-illustrated fan containment housing), and accelerates the air. A fraction of the accelerated air exhausted from the fan <NUM> is directed through an outer bypass duct <NUM> and the remaining fraction of air exhausted from the fan <NUM> is directed into the compressor section <NUM> along a core flow path <NUM>. The outer bypass duct <NUM> is generally defined between the inner casing <NUM> and an outer casing <NUM>, which may comprise non-illustrated forward and aft outer bypass ducts. The compressor section <NUM> includes one or more stages <NUM>, which will be discussed in greater detail below. The compressor section <NUM> sequentially raises the pressure of the air and directs a majority of the high-pressure air into the combustor section <NUM>.

In the combustor section <NUM>, which includes a combustion chamber <NUM>, the high-pressure air is mixed with fuel, which is combusted. The high-temperature combustion air is directed into the turbine section <NUM>. In this example, the turbine section <NUM> includes three turbines disposed in axial flow series, namely, a high-pressure turbine <NUM>, an intermediate pressure turbine <NUM>, and a low-pressure turbine <NUM>. However, it will be appreciated that the number of turbines, and/or the configurations thereof, may vary. In this embodiment, the high-temperature air from the combustor section <NUM> expands through and rotates each turbine <NUM>, <NUM>, and <NUM>. As the turbines <NUM>, <NUM>, and <NUM> rotate, each drives equipment in the gas turbine engine <NUM> via concentrically disposed shafts or spools. In one example, the high-pressure turbine <NUM> and the intermediate pressure turbine <NUM> drives the stages <NUM> in the compressor section <NUM> via shafts <NUM>, <NUM>, and the low-pressure turbine <NUM> drives the fan <NUM> via a shaft <NUM>.

As noted previously, various components that comprise the turbomachine <NUM> are coupled together. For example, portions of the fan section <NUM> may be coupled to the compressor section <NUM>, portions of the compressor section <NUM> may be coupled to the combustor section <NUM>, and portions of the compressor section <NUM> may be coupled to the turbine section <NUM>, just to name a few of the turbomachine components that are coupled together. One example of two turbomachine components - a first component <NUM> and a second component <NUM> - that are coupled together according to the configuration and methods described herein is depicted in <FIG>.

As shown in <FIG>, the first component <NUM> extends about an axis of symmetry <NUM> (which may correspond to the longitudinal axis <NUM> of <FIG>) from a first component mating end <NUM> to an opposing first component second end <NUM>. The second component <NUM> also extends about the axis of symmetry <NUM>, but from a second component mating end <NUM> to an opposing second component second end <NUM>. The first component mating end <NUM> and the second component mating end <NUM> each include attachment flanges. In particular, the first component <NUM> has a plurality of internal attachment flanges <NUM> that are spaced evenly around the first component mating end <NUM>, and the second component <NUM> has a plurality of external attachment flanges <NUM> that are spaced evenly around the second component mating end <NUM>. Although not depicted as such, it will be appreciated that either, or both, of the first and second component second ends <NUM>, <NUM> may, if needed, include internal or external attachment flanges <NUM>, <NUM>.

As shown more clearly in <FIG>, each internal attachment flange <NUM> includes a first component flange section <NUM> and a mating section <NUM> that is coupled to the first component flange section <NUM>. Each first component flange section <NUM> extends radially from the first component mating end <NUM> and is disposed perpendicular to the axis of symmetry <NUM>. Each mating section <NUM> is spaced apart from the first component mating end <NUM> and extends parallel to the axis of symmetry <NUM>. In some embodiments, such as the one depicted herein, the first component mating end <NUM> and the second component mating end <NUM> may each include conically shaped portions <NUM>, <NUM>, which engage each other and allow high-speed air to flow from the first component <NUM> into the second component <NUM> with minimal turbulence.

Each external attachment flange <NUM> includes a second component flange section <NUM> and a receptacle section <NUM>. Each second component flange section <NUM> extends radially from the second component mating end <NUM> and is disposed perpendicular to the axis of symmetry <NUM>. Each receptacle section <NUM> includes a first arm <NUM>, a second arm <NUM>, and a third arm <NUM> that is connected to the first and second arms <NUM>, <NUM>. The first and second arms <NUM>, <NUM> of each receptacle section <NUM> extend parallel to the axis of symmetry <NUM> and are spaced apart from each other, and the third arm <NUM> of each receptacle section <NUM> extends perpendicular to the axis of symmetry <NUM>. As such, each receptacle section <NUM> defines a receptacle section cavity <NUM> that is dimensioned to receive one of the mating sections <NUM>. Indeed, as <FIG> and <FIG> clearly depict, the mating section <NUM> of each internal attachment flange <NUM> is associated with, and is disposed within, the receptacle section cavity <NUM> of a different one of the external attachment flanges <NUM>, to thereby define a plurality of mating flange pairs <NUM>.

Referring briefly to <FIG>, which depicts an end view of the first and second components <NUM>, <NUM> coupled together, it is seen that the illustrated embodiment includes <NUM> mating flange pairs <NUM>. It will be appreciated that this is merely exemplary, and that the first and second components <NUM>, <NUM> could be configured to include more or less than this number of mating flange pairs <NUM>.

Returning once again to <FIG>, it is seen that each first component flange section <NUM> includes at least a flange section axial pilot face <NUM>, and each mating section <NUM> includes at least a mating section radial pilot face <NUM> and a mating section axial pilot face <NUM>. It is additionally seen that each flange section axial pilot face <NUM> engages its associated second component flange section <NUM>. Moreover, each mating section radial pilot face <NUM> engages the second arm <NUM> of its associated external attachment flange <NUM>, and each mating section axial pilot face <NUM> engages the third arm <NUM> of it associated external attachment flange <NUM>.

When it is desirable to ensure the first and second components <NUM>, <NUM> can only be coupled together one specific way, the first and second components <NUM>, <NUM> may additionally be configured such that a subset of the mating flange pairs <NUM> each includes an anti-rotation feature. This subset of mating flange pairs, as is depicted in <FIG>, are referred to herein as anti-rotation mating flange pairs <NUM>. More specifically, and as shown more clearly in <FIG>, a first subset of the internal attachment flanges <NUM> each include a first anti-rotation feature <NUM> and a second subset of the external attachment flanges <NUM> each include a second anti-rotation feature <NUM>. Although the configuration and implementation of the first and second anti-rotation features <NUM>, <NUM> may vary, in the depicted embodiment, the first and second anti-rotation features <NUM>, <NUM> each includes a fastener opening. With this configuration, fastener hardware <NUM>, such as a bolt (as shown in <FIG>) or a bolt and a nut (not shown), may extend through a different one of the anti-rotation mating flange pairs <NUM>.

Preferably, and as <FIG> also depicts, the plurality of anti-rotation flange pairs <NUM> are spaced asymmetrically about the axis of symmetry <NUM>. More specifically, if there are two anti-rotation mating flange pairs <NUM>, these should not be spaced <NUM>-degrees apart, but should instead be spaced apart by some other angle such as, for example,<NUM>- or <NUM>-degrees. Similarly, if there are three anti-rotation mating flange pairs <NUM>, as depicted in the embodiment in <FIG>, these features should not be spaced <NUM>-degrees apart. Instead, these features should be spaced apart by some other angle such as, for example, <NUM>- or <NUM>-degrees. In addition to ensuring the first and second components <NUM>, <NUM> can only be coupled together one specific way, the spacing of the anti-rotation mating flange pairs <NUM> can be strategically located, away from high congestion areas, such as a gearbox, to allow easier assembly.

Referring now to <FIG>, it is seen that the particular shapes of portions of the internal attachment flanges <NUM> may vary. In particular, at least in the embodiment depicted therein, portions of the first component flange section <NUM> and/or portions of the mating section <NUM> may be chamfered and/or beveled. It will additionally be appreciated that, although in the embodiments depicted in at least <FIG> and <FIG> the first component <NUM> is disposed upstream of the second component <NUM>, this need not always be the case. Indeed, in alternative embodiments, such as the one depicted in <FIG>, the first component <NUM> may be disposed downstream of the second component <NUM>.

One example method of assembling the first and second components <NUM>, <NUM> will be described momentarily. Before doing so, it may be appreciated that, at least in some embodiments, the internal and/or external attachment flanges <NUM>, <NUM> may be implemented with one or more features to facilitate the assembly process. For example, as <FIG>, <FIG>, and <FIG> depict, at least a portion (or all) of each flange section axial pilot face <NUM>, at least a portion (or all) of each mating section radial pilot face <NUM>, and at least a portion (or all) of each mating section axial pilot face <NUM> may be coated with a low-friction material <NUM>. In some embodiments, at least a portion of the first component mating end <NUM> may also be coated with the low-friction material <NUM>. The particular low friction material may vary. In one embodiment, it is a material that comprises polytetrafluoroethylene (PTFE) (e.g., an impregnated PTFE material). In other embodiments the low-friction material <NUM> may be anodizing, chromate conversion, polished surfaces, and dry film lubrication, just to name a few.

Another technique to facilitate the assembly process is depicted in <FIG>. As depicted therein, it is seen that at least the mating section <NUM> of each internal attachment flange <NUM> may include a double chamfered first end <NUM> and a double chamfered second end <NUM>. In some embodiments, such as the one depicted in <FIG>, first and second ends <NUM>, <NUM> of the first component flange section <NUM> may also include chamfers.

With reference now to <FIG>, one example method of assembling the first and second components <NUM>, <NUM> will now be described. Initially, as depicted in <FIG>, the first and second components <NUM>, <NUM> having the plurality of internal attachment flanges <NUM> and plurality of external attachment flanges <NUM>, respectively, are provided. The first and second component mating ends <NUM>, <NUM> are then abutted, as shown in <FIG>, in a manner that (i) each internal attachment flange <NUM> is radially disposed between two adjacent external attachment flanges <NUM> and (ii) each internal attachment flange <NUM> that includes a first anti-rotation feature <NUM> is radially disposed adjacent one of the external attachment flanges <NUM> that includes a second anti-rotation feature <NUM>. Thereafter, relative rotation is provided between the first component <NUM> and the second component <NUM>. The relative rotation may be provided by rotating only the first component <NUM>, rotating only the second component <NUM>, or rotating both the first component and the second component <NUM>.

Regardless of how the relative rotation is provided, it continues, as depicted in <FIG>, until the mating section <NUM> of each internal attachment flange <NUM> is disposed within the receptacle section cavity <NUM> of one of the two adjacent external attachment flanges <NUM>, and such that each of the first anti-rotation features <NUM> is aligned with a different one of the second anti-rotation features <NUM>. As <FIG> also depicts, when the first and second anti-rotation features <NUM>, <NUM> are implemented as fastener openings, fastener hardware <NUM> may then be extended through each fastener opening.

The turbomachine components and coupling methods do not rely on a time-consuming process of installing fastener hardware at each mating interface flange and/or does not limit the clocking of certain components, such as thrust reverser components. For example, to illustrate this, <FIG> depicts an embodiment in which the first structure corresponds to a nacelle inlet structure <NUM> and the second structure corresponds to a fan inlet containment housing <NUM>. With the currently known components and coupling methods, which is depicted in <FIG>, fastener hardware (not illustrated) must be installed at each mating flange interface <NUM> for these components <NUM>, <NUM>. The castellated flanges depicted and described herein also provide an improved retention method for retaining the nacelle inlet to the fan containment housing in the event of a "fan blade loss rotating unbalance loading" enabling the flanges to remain intact and not lose an inlet assembly during or subsequent to the event, and is far superior in retention than bolts and nuts for massive unbalance loading.

As used herein, the term "axial" refers to a direction that is generally parallel to or coincident with an axis of rotation, axis of symmetry, or centerline of a component or components. For example, in a cylinder or disc with a centerline and generally circular ends or opposing faces, the "axial" direction may refer to the direction that generally extends in parallel to the centerline between the opposite ends or faces. In certain instances, the term "axial" may be utilized with respect to components that are not cylindrical (or otherwise radially symmetric). For example, the "axial" direction for a rectangular housing containing a rotating shaft may be viewed as a direction that is generally parallel to or coincident with the rotational axis of the shaft. Furthermore, the term "radially" as used herein may refer to a direction or a relationship of components with respect to a line extending outward from a shared centerline, axis, or similar reference, for example in a plane of a cylinder or disc that is perpendicular to the centerline or axis. In certain instances, components may be viewed as "radially" aligned even though one or both of the components may not be cylindrical (or otherwise radially symmetric). Furthermore, the terms "axial" and "radial" (and any derivatives) may encompass directional relationships that are other than precisely aligned with (e.g., oblique to) the true axial and radial dimensions, provided the relationship is predominantly in the respective nominal axial or radial direction. As used herein, the term "substantially" denotes within <NUM>% to account for manufacturing tolerances. Also, as used herein, the term "about" denotes within <NUM>% of a value to account for manufacturing tolerances.

Claim 1:
A turbomachine, comprising:
a first component (<NUM>) that extends about an axis of symmetry (<NUM>) from a first component mating end (<NUM>) to an opposing first component second end, the first component having a plurality of internal attachment flanges (<NUM>) spaced evenly around the first component mating end, each internal attachment flange including a first component flange section (<NUM>) and a mating section (<NUM>) coupled to the first component flange section, each first component flange section extending radially from the first component mating end and disposed perpendicular to the axis of symmetry, each mating section spaced apart from the first component mating end and extending parallel to the axis of symmetry; and
a second component (<NUM>) that extends about the axis of symmetry from a second component mating end (<NUM>) to an opposing second component second end (<NUM>), the second component coupled to the first component and having a plurality of external attachment flanges (<NUM>) spaced evenly around the second component mating end, each external attachment flange including a second component flange section and a receptacle section (<NUM>), each second component flange section extending radially from the second component mating end and disposed perpendicular to the axis of symmetry, characterised by each receptacle section including a first arm (<NUM>), a second arm (<NUM>), and a third arm (<NUM>) that is connected to the first and second arms, wherein the first and second arms of each receptacle section extend parallel to the axis of symmetry and are spaced apart from each other, and the third arm of each receptacle section extends perpendicular to the axis of symmetry, whereby each receptacle section defines a receptacle section cavity (<NUM>) dimensioned to receive one of the mating sections,
wherein:
the mating section of each internal attachment flange is associated with, and is disposed within, the receptacle section cavity of a different one of the external attachment flanges, to thereby define a plurality of mating flange pairs (<NUM>), and
a subset of the mating flange pairs each includes an anti-rotation feature (<NUM>, <NUM>), to thereby define a plurality of anti-rotation mating flange pairs.