Automating Turbine Rotor Shaft Design for Faster, Error-Free Modeling

Objective

To streamline the design of turbine rotor shafts by automating model generation and customization through a user-friendly interface. This module was developed as an extension to the previously automated diaphragm assembly workflow, with the goal of reducing manual effort and minimizing design errors.

The Scope

The turbine rotor shaft is a critical component in turbine assembly, serving as the structural base for rotor blades and diaphragm rings. Previously, each rotor shaft required manual customization to fit project-specific specifications — a process prone to delays and inconsistencies, especially under high workload conditions.

By automating this task, we aimed to reduce design time, eliminate repetitive modeling, and allow engineers to focus on higher-value work.

The Solution

We developed a standalone program integrated into the existing diaphragm automation system. The tool generates fully customized rotor shaft models based on a small set of high-impact parameters. It intelligently handles all geometry creation and adjusts dimensions to meet technical requirements.

Key to this solution is the clean and intuitive User Interface, designed for both technical and non-technical users. The UI features large icons, simple inputs, and dynamic validation, making it easy to operate even with minimal CAD expertise.

User Interface Parameters and Features

The automation system interprets design logic from standard engineering data sources, including drawing files, calculation sheets, and reference tables. Once processed, it creates ready-to-use models with no manual intervention required.

Key parameters include:

• Pitch Circle Diameter

• Blade Height

• Disc Width

• Bleed Stage Removal (select stages to be excluded)

• Stage-Level Customization (modify individual stage geometry)

• Rough Machining Options (for manufacturing-ready versions)

Each parameter is tightly linked to configurable rules, allowing the system to produce consistent, fabrication-aligned outputs every time.

Impact

• Significant time savings in rotor shaft modeling across multiple projects

• Reduced design errors with rule-based logic and UI-driven customization

• Simplified interface enabled quicker onboarding and easier adoption

• Improved design team efficiency, with reduced dependency on CAD experts

This automation module helps the engineering team produce consistent, error-free rotor designs — faster and with fewer resources — while supporting complex customization needs.