Bearing system with independent adaptive stiffness support

Abstract

A bearing system is provided, which is configured to surround a rotor in a circumferential direction corresponding to the rotor. The rotor extends in an axial direction that is the same direction as the centerline axis of the rotor. The bearing system includes a body, a plurality of first support members each extend from the body, and wherein the plurality of first support members are spaced apart from each other in the circumferential direction. Each first support member includes a first axial support arm extending in the axial direction and a first radial support arm extending from the first axial support arm in a radial direction. The first radial support arm is configured to position a bearing element to contact a bearing surface at the rotor.

Description

Technical Field

[0001] The present subject matter generally relates to bearing assemblies. In particular, the present subject matter relates to bearing assemblies for bladed rotor assemblies. Background Art

[0002] Rotor assemblies, such as turbines and wind turbines, are often challenged to operate under various rotor dynamic conditions. The rotor dynamics of a rotor assembly may be affected by thrust output, loads, rotational speed, thermal gradients, mass, diameter, static or dynamic imbalance, or changes therein during operation of the rotor assembly. Various operating conditions may result in undesirable vibration responses, rotations, imbalances, or vibration modes. Such operating conditions may generate structural stresses that inhibit desired operations, such as desired thrust output, loads, or rotational speeds, or result in reduced structural life or component failure.

[0003] While rotor assemblies in general are subject to the challenges described above, larger diameter or larger mass rotor assemblies, such as wind turbines or interdigitated rotor assemblies with rotatable outer drums, are particularly subject to the challenges described above. There is a need for bearing assemblies that can improve vibration response, improve rotational stability, and adapt to a variety of operating conditions. Summary of the invention

[0004] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0005] One aspect of the present disclosure is directed to a bearing system configured to surround a rotor in a circumferential direction corresponding to a rotor. The rotor extends in an axial direction that is in the same direction as the centerline axis of the rotor. The bearing system includes a body, a plurality of first support members each extending from the body, and wherein the plurality of first support members are spaced apart from each other in the circumferential direction. Each first support member includes a first axial support arm extending in the axial direction and a first radial support arm extending in a radial direction from the first axial support arm. The first radial support arm is configured to position a bearing element to contact a bearing surface at the rotor.

[0006] Another aspect of the present disclosure is directed to a gas turbine engine having a fan assembly. The fan assembly includes a plurality of fan blades and a wheel blade assembly. One or both of the wheel blade assembly or the plurality of fan blades can be adjusted along a corresponding pitch axis. The core engine is configured to drive the plurality of fan blades of the fan assembly. A bearing system is positioned at one or more of the core engine, the plurality of fan blades, or the wheel blade assembly. The bearing system is configured to surround the rotor at the core engine or the fan assembly along a circumferential direction corresponding to the rotor. The rotor extends in an axial direction that is in the same direction as the centerline axis of the rotor. The bearing system includes a body, and a plurality of first support members each extend from the body. The plurality of first support members are spaced apart from each other along the circumferential direction. Each first support member includes a first axial support arm extending in the axial direction and a first radial support arm extending in a radial direction from the first axial support arm. The first radial support arm is configured to position a bearing element to contact a bearing surface at the rotor.

[0007] Another aspect of the present disclosure is directed to a wind turbine. The wind turbine includes a tower extending from a support surface. A nacelle is mounted to the tower. A rotor is coupled to the nacelle. The rotor includes a rotatable hub and rotor blades coupled to the hub. A bearing system is positioned at one or more of the rotor or the rotor blades. The bearing system is configured to surround the rotor along a circumferential direction corresponding to the rotor. The rotor extends in an axial direction that is in the same direction as the centerline axis of the rotor. The bearing system includes a body, and a plurality of first support members each extend from the body. A plurality of first support members are spaced apart from each other along the circumferential direction. Each first support member includes a first axial support arm extending in the axial direction and a first radial support arm extending in a radial direction from the first axial support arm. The first radial support arm is configured to position a bearing element to contact a bearing surface at the rotor.

[0008] These and other features, aspects and advantages of the present invention will be better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and together with the description serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] This specification sets forth a complete and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art with reference to the accompanying drawings, in which:

[0010] Figure 1 is a schematic diagram of an exemplary embodiment of a wind turbine including a bearing system according to aspects of the present disclosure;

[0011] Figure 2 A bearing system including the bearing system according to various aspects of the present disclosure is provided. Figure 1 A schematic perspective partial cutaway view of a nacelle and a rotor of a wind turbine;

[0012] Figure 3 A bearing system including the bearing system according to various aspects of the present disclosure is provided. Figure 1 A schematic perspective partial cutaway view of a nacelle and a rotor of a wind turbine;

[0013] Figure 4 is a schematic cross-sectional view of an exemplary embodiment of a turbine engine including a bearing system according to an aspect of the present disclosure;

[0014] Figure 5 is a cutaway side view of an exemplary embodiment of a turbine engine including a bearing system according to an aspect of the present disclosure;

[0015] Figure 6 According to one aspect of the present disclosure Figure 4-5 An exemplary schematic embodiment of a turbine of;

[0016] Figure 7 yes Figure 4-6 A detailed view of a schematic interleaved rotor assembly of a turbine of including a bearing system according to aspects of the present disclosure;

[0017] Figure 8 is a perspective view of an embodiment of a bearing system according to aspects of the present disclosure;

[0018] Fig. 9 is a side cross-sectional view of a portion of an embodiment of a bearing system according to aspects of the present disclosure;

[0019] Fig.10 is a perspective view of an embodiment of a bearing system according to aspects of the present disclosure;

[0020] Fig.11 is a side cross-sectional view of a portion of an embodiment of a bearing system according to aspects of the present disclosure;

[0021] Fig.12 is a perspective view of an embodiment of a bearing system according to aspects of the present disclosure;

[0022] Fig.13 is a side cross-sectional view of a portion of an embodiment of a bearing system according to aspects of the present disclosure;

[0023] Fig.14 yes Figure 8-11 An exemplary illustrative embodiment of a portion of a bearing system of; and

[0024] Fig.15 yes Figure 8-11 An exemplary illustrative embodiment of a portion of a bearing system.

[0025] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0026] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the present invention, rather than limitation thereof. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made to the present invention without departing from the scope or spirit of the present invention. For example, a feature shown or described as part of one embodiment may be used together with another embodiment to produce a further embodiment. Therefore, the present invention is intended to encompass these modifications and variations within the scope of the appended claims and their equivalents.

[0027] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations.

[0028] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and not for the purpose of indicating the position or importance of each component.

[0029] The terms "front" and "rear" refer to relative positions within a gas turbine engine or vehicle and refer to the normal operating attitude of the gas turbine engine or vehicle. For example, in the case of a gas turbine engine, the front refers to a position near the engine air intake and the rear refers to a position near the engine nozzle or exhaust.

[0030] The terms "upstream" and "downstream" refer to relative directions relative to the flow of a fluid in a fluid path. For example, "upstream" refers to the direction from which the fluid is flowing, while "downstream" refers to the direction to which the fluid is flowing.

[0031] The terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attachment as well as indirect coupling, fixing, or attachment through one or more intermediate components or features, unless otherwise specified herein.

[0032] The singular forms "a", "an" and "the" include plural forms unless the context clearly dictates otherwise.

[0033] As used herein throughout the specification and claims, approximating language is applied to modify any quantitative representation that can be permissibly varied without resulting in a change in the basic function to which it is related. Thus, values ​​modified by one or more terms, such as "about," "approximately," and "substantially," are not limited to the precise values ​​specified. Approximate language may correspond to the precision of an instrument used to measure a value, or the precision of a method or machine used to construct or manufacture a component and / or system, at least in some cases. For example, approximate language may refer to within a margin of 1, 2, 4, 10, 15, or 20%.

[0034] Here and throughout the specification and claims, range limitations are combined and interchanged, such ranges are identified and include all sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein include the endpoints, and the endpoints are independently combinable with each other.

[0035] One or more components of the bearing system described below may be manufactured or formed using any suitable process, such as an additive manufacturing process, such as a 3D printing process. Use of such a process may allow such components to be formed in one piece, as a single integral component, or as any appropriate number of subcomponents. In particular, the additive manufacturing process may allow such components to be formed in one piece and include various features that were not possible when using previous manufacturing methods. For example, the additive manufacturing methods described herein may allow the manufacture of a body, shell, support arm, channel, or other features of a bearing system having unique features, configurations, thicknesses, materials, densities, and fluid passages, or combinations thereof, which may not be possible or practical using previous manufacturing methods. Some of these features are described herein.

[0036] Suitable additive manufacturing techniques according to the present disclosure include, for example, fused deposition modeling (FDM), selective laser sintering (SLS), 3D printing (such as by inkjet, laser jetting, and binder jetting), stereolithography (SLA), direct selective laser sintering (DSLS), electron beam sintering (EBS), electron beam melting (EBM), laser engineered net shaping (LENS), laser net shape manufacturing (LNSM), direct metal deposition (DMD), digital light processing (DLP), direct selective laser melting (DSLM), selective laser melting (SLM), direct metal laser melting (DMLM), and other known processes.

[0037] Now referring to the accompanying drawings, Figure 1A perspective view of one embodiment of a conventional wind turbine 1000 in which aspects of the present systems and methods are implemented is illustrated. The wind turbine 1000 includes a tower 1012 extending from a support surface 1014, a nacelle 1016 mounted on the tower 1012, and a rotor 1018 coupled to the nacelle 1016. The rotor 1018 includes a rotatable hub 1020 and at least one rotor blade 1022 coupled to the hub 1020 and extending outwardly from the hub 1020. For example, in the illustrated embodiment, the rotor 1018 includes three rotor blades 1022. Each rotor blade 1022 is spaced about the hub 1020 to facilitate rotation of the rotor 1018, enabling kinetic energy to be converted from the wind into usable mechanical energy and subsequently into electrical energy. For example, the hub 1020 is rotatably coupled to a generator 1024 ( Figure 2 ) are connected to generate electrical energy.

[0038] Wind turbine 1000 may also include a wind turbine controller 1026 centralized within nacelle 1016, or located within any other component of wind turbine 1000, or located at a location external to the wind turbine. Furthermore, controller 1026 may be communicatively coupled to any number of components of wind turbine 1000 in order to operate the components and / or implement the pitch control functionality described herein.

[0039] Reference Figure 2 , illustrating an internal view of a conventional nacelle 1016. As shown, a generator 1024 is coupled to a rotor 1018 for generating electricity from the rotational energy generated by the rotor 1018. The rotor 1018 may include a rotor shaft 1034 coupled to the hub 1020 so as to rotate therewith. The rotor shaft 1034 is rotatably coupled to the generator shaft 36 of the generator 1024 through a gearbox 1038. As generally understood, the rotor shaft 1034 provides a low-speed, high-torque input to the gearbox 1038 in response to the rotation of the rotor blades 1022 and the hub 1020. The gearbox 1038 is configured to convert the low-speed, high-torque input into a high-speed, low-torque output to drive the generator shaft 36, thereby driving the generator 1024. The wind turbine 1000 may also include a converter (not shown) configured to connect the generator 1024 to a power grid and ensure a constant supply of energy. More specifically, the converter is configured to convert a predetermined torque demand into rotational power to drive the generator 1024.

[0040] Wind turbine 1000 may include one or more yaw drive mechanisms 66 communicatively coupled to controller 1026 , wherein each yaw drive mechanism 66 is configured to change the angle of nacelle 1016 relative to the wind (eg, by engaging a yaw bearing 68 of wind turbine 1000 ).

[0041] Wind turbine 1000 includes a pitch control system in which each rotor blade 1022 has a pitch adjustment mechanism 1032 configured to rotate each rotor blade 1022 about its pitch axis 1028 ( Figure 1 ). In addition, each pitch adjustment mechanism 1032 may include a pitch drive motor 1040 (e.g., any suitable electric, hydraulic, or pneumatic motor), a pitch drive gearbox 1042, and a pitch drive pinion 1044. In such an embodiment, the pitch drive motor 1040 may be coupled to the pitch drive gearbox 1042 so that the pitch drive motor 1040 applies a mechanical force to the pitch drive gearbox 1042. Similarly, the pitch drive gearbox 1042 may be coupled to the pitch drive pinion 1044 to rotate therewith. The pitch drive pinion 1044 may, in turn, be rotationally engaged with a pitch bearing 1046 coupled between the hub 1020 and the corresponding rotor blade 1022, such that rotation of the pitch drive pinion 1044 causes rotation of the pitch bearing 1046. Thus, in such embodiments, rotation of pitch drive motor 1040 drives pitch drive gearbox 1042 and pitch drive pinion 1044, thereby rotating pitch bearing 1046 and rotor blades 1022 about pitch axis 1028. The pitch control system is controlled by controller 1026 to pitch blades 1022 according to various control and power generation parameters. In certain embodiments, power for the pitch control system, and in particular drive motor 40, is supplied from a downstream power grid.

[0042] Figure 3 Provided Figure 1-2 A partially cutaway perspective view of the interior of a rotor 1018 of an exemplary wind turbine 1000. Positioned at the rotor shaft 1034 is a bearing system 105, which is configured as described with respect to Figure 8-15 The invention is depicted and described in one or more embodiments of the present invention.

[0043] Now referring to the accompanying drawings, Figure 4-51 is an exemplary embodiment of an engine 10 including an interleaved turbine assembly according to various aspects of the present disclosure. The engine 10 includes a fan assembly 14 driven by a core engine 16. The core engine 16 is enclosed in a housing 18. In various embodiments, the core engine 16 is typically a Brayton cycle system that is configured to drive the fan assembly 14. However, in other embodiments, the fan assembly 14 can be driven by a core engine that is configured as a boost system or a hybrid electric system, including an electric power system with one or more motors, energy storage devices, motor / generators, or controllers. The core engine 16 is at least partially covered by the housing 18. The fan assembly 14 includes a plurality of fan blades 13. A blade assembly 20 extends from the housing 18. The blade assembly 20, including a plurality of blades 15, is positioned to be operably arranged with the fan blades 13 to provide thrust, control thrust vectoring, reduce or redirect undesirable acoustic noise, or otherwise change the flow of air relative to the fan blades 13 in a desired manner.

[0044] In certain embodiments, such as Figure 4-5 As described in the drawings, the blade assembly 20 is positioned downstream or rearward of the fan assembly 14. However, it should be understood that in some embodiments, the blade assembly 20 may be positioned upstream or forward of the fan assembly 14. In various embodiments, the engine 10 may include a first blade assembly positioned forward of the fan assembly 14 and a second blade assembly positioned rearward of the fan assembly 14. The fan assembly 14 may be configured to adjust the pitch at one or more fan blades 13 as desired. In some embodiments, such as Figure 5 As described, the pitch-adjustable fan blades 13 can control thrust vectoring, reduce or redirect noise, or vary thrust output. The blade assembly 20 can be configured to desirably adjust the pitch at one or more blades 15, for example, to control thrust vectoring, reduce or redirect noise, or vary thrust output. The pitch control mechanisms at one or both of the fan assembly 14 or the blade assembly 20 can cooperate to produce one or more of the desired effects described above. In certain embodiments, the pitch control mechanisms at one or both of the fan assembly 14 or the blade assembly 20 include embodiments of the bearing system further described herein.

[0045] In various embodiments, such as Figure 4 As described, engine 10 is a ducted thrust generating system. Engine 10 may be configured as a turbofan, with a nacelle or fan case 54 enclosing a plurality of fan blades 13. In certain embodiments, such as Figure 5As described, the engine 10 is a non-ducted thrust generating system such that the plurality of fan blades 13 are not covered by a nacelle or fan case. Thus, in various embodiments, the engine 10 may be configured as an unshrouded turbofan engine, an open rotor engine, or a propeller fan engine. In a particular embodiment, the engine 10 is a single non-ducted rotor engine including a single row of fan blades 13.

[0046] The engine 10 may be configured as a low bypass or high bypass engine with appropriately sized fan blades 13. An engine 10 configured as an open rotor engine may include a fan assembly 14 with large diameter fan blades 13, such as may be suitable for a high bypass ratio, a high cruise speed (e.g., compared to an aircraft with a turbofan engine, or generally higher than the cruise speed of an aircraft with a turboprop engine), a high cruise altitude (e.g., compared to an aircraft with a turbofan engine, or generally higher than the cruise speed of an aircraft with a turboprop engine), and / or a relatively low rotation speed. The cruise altitude generally refers to the level flight altitude of an aircraft after a climb and before descending to the approach flight phase.

[0047] Reference now Figure 6 , an exemplary schematic embodiment of a core engine 16 is provided. The core engine 16 includes a compressor section 21, a heating system 26, and a turbine section 33 arranged in series flow. The core engine 16 extends circumferentially relative to the engine centerline axis 12. The core engine 16 includes a high-speed spool, which includes a high-speed compressor 24 and a high-speed turbine 28 that are operably and rotationally coupled together by a high-speed shaft 22. The heating system 26 is positioned between the high-speed compressor 24 and the high-speed turbine 28. Various embodiments of the heating system 26 include a combustion section. The combustion section can be configured as a deflagration combustion section, a rotating detonation combustion section, a pulse detonation combustion section, or other suitable heating systems. The heating system 26 can be configured as one or more of a rich combustion system or a lean combustion system, or a combination thereof. In different embodiments, the heating system 26 includes an annular combustor, a can combustor, a can annular combustor, a trapped vortex combustor (TVC), or other suitable combustion systems, or a combination thereof.

[0048] Still reference Figure 6, the core engine 16 includes a supercharger or low-speed compressor 23 positioned in a flow relationship with the high-speed compressor 24. The low-speed compressor 23 is rotatably coupled to the turbine section 33 via a drive shaft 29. Various embodiments of the turbine section 33 further include a turbine rotor assembly 100, which includes a second rotor assembly 120 and a first rotor assembly 110 that are interlaced with each other. The second rotor assembly 120 and the first rotor assembly 110 are each operably connected to the gear assembly 300 to provide power to the fan assembly 14 and the low-speed compressor 23, as further described herein. In certain embodiments, the second rotor assembly 120 and the first rotor assembly 110 are positioned together downstream of the high-speed turbine 28.

[0049] It should be understood that the terms "low" and "high", or their corresponding comparatives (e.g., lower, where applicable), when used with compressor, turbine, shaft or spool components, each refer to relative speeds within the engine, unless otherwise specified. For example, a "low turbine" or "low-speed turbine" defines a component that is configured to operate at a speed (such as the maximum allowable speed) lower than a "high turbine" or "high-speed turbine" at the engine. In addition, unless otherwise specified, the above terms may be understood in their superlative form. For example, a "low turbine" or "low-speed turbine" may refer to the turbine with the lowest maximum speed within the turbine section, a "low compressor" or "low-speed compressor" may refer to the turbine with the lowest maximum speed within the compressor section, a "high turbine" or "high-speed turbine" may refer to the turbine with the highest maximum speed within the turbine section, and a "high compressor" or "high-speed compressor" may refer to the compressor with the highest maximum speed within the compressor section. Similarly, a low-speed spool refers to a lower maximum speed than a high-speed spool. It should be further understood that the terms "low" or "high" in the above aspects may additionally or alternatively be understood as relative to a minimum allowable speed, or relative to a minimum or maximum allowable speed for normal, desired, steady state, etc. operation of the engine.

[0050] In some embodiments, for example, Figure 6 As described in , the core engine 16 includes one or more staggered structures at the compressor section 21 and / or the turbine section 33. In one embodiment, the turbine section 33 includes a turbine rotor assembly including a first rotor assembly 110, which is interleaved with a second rotor assembly 120, such as via a rotating outer shroud, drum, casing, or rotor. It should be understood that embodiments of the turbine section 33 may include a first turbine 110 and / or a second turbine 120 that are interleaved with one or more stages of a high-speed turbine 28. In another embodiment, the compressor section 21 includes a low-speed compressor 23 that is interleaved with a high-speed compressor 24. For example, a higher speed compressor (such as the high-speed compressor 24) may be a first compressor that is interleaved with a lower speed compressor (such as the low-speed compressor 23).

[0051] Figure 4-7 The various embodiments of the engine 10 provided in further include a bearing system positioned at one or more of the compressor section 21 or the turbine section 33. In certain embodiments, the bearing system 45 is positioned at a shaft, such as the high-speed shaft 22 or the drive shaft 29. The bearing system 45 can be positioned at one or more locations or stations of the engine 10, such as at the front drive shaft bearing or referred to as bearing No. 1 or No. 2; or at the front high-speed shaft bearing or referred to as bearing No. 3; or at the rear high-speed shaft bearing or referred to as bearing No. 4; or at the rear drive shaft bearing or referred to as bearing No. 5 or No. 6. In other embodiments, the bearing system can be positioned at the outer diameter of the staggered rotor assembly, such as at Figure 6 , at the bearing system 25 at the compressor section 21, or at the bearing system 35 at the turbine section 33. In various embodiments, the bearing systems 25, 35, 45 are configured as described herein. Figure 8-15 One or more bearing systems depicted and described herein.

[0052] Brief reference Figure 8 , an exemplary schematic diagram of a portion of an interleaved rotor assembly 100 including an outer diameter bearing assembly 107 is provided. In one embodiment, the interleaved rotor assembly 100 may be configured as a compressor section 21 including a low speed compressor 23 and / or a high speed compressor 24, such as Figure 6 In other embodiments, the outer diameter bearing assembly 107 may be positioned at any combination of interleaved compressors not described herein, such as a combination of low-speed, medium-speed, or high-speed compressors or fan assemblies. In another embodiment, the interleaved rotor assembly 100 may be configured as a turbine section 33 including a first rotor assembly 110 and a second rotor assembly 120. In other embodiments, the outer diameter bearing assembly 107 may be positioned at any combination of interleaved turbines not described herein, such as a combination of high-speed, medium-speed, or low-speed turbines.

[0053] Reference again Figure 7 , the interleaved rotor assembly 100 generally includes an outer drum rotor assembly 150 interleaved with an inner rotor assembly 160. The outer drum rotor assembly 150 has a plurality of outer drum rotor blades 152 attached to a rotatable outer drum or shroud 154 and extending inwardly in a radial direction R from the rotatable outer drum or shroud 154. The inner rotor assembly 160 has a plurality of inner rotor blades 162 extending outwardly in a radial direction R from a disk or drum. A static or stationary housing 170 surrounds the outer drum rotor assembly 150. The outer diameter bearing assembly 107 is positioned between the housing 170 and the outer drum rotor assembly 150. As further described herein, the present invention relates to Figure 8-15The stationary or static portion of the described bearing assembly is operably coupled to the housing 170. Figure 8 In the embodiment, Figure 8-15 The rotor depicted in is generally the outer drum 154 of the interleaved rotor assembly 100 .

[0054] Although described as an unshrouded or open rotor engine, it should be understood that aspects of the disclosure provided herein may be applied to shrouded or ducted engines, partially ducted engines, rear fan engines, or other turbine configurations, including those used in marine, industrial, or aerospace propulsion systems. Certain aspects of the disclosure may be applicable to turbofans, turboprops, or turboshaft engines, such as turbofans, turboprops, or turboshaft engines with reduction gear assemblies.

[0055] Reference now Figure 8 , an embodiment of a bearing system 400 according to aspects of the present disclosure is provided. The bearing system 400 includes a body 402 from which a first support member 410 and a second support member 420 each extend. In a particular embodiment, the body 402 is an annular static structure extending in a circumferential direction C relative to a centerline axis 401. The body 402 is formed to surround a rotor 50 extending through an opening 54. The opening 54 passes through the body 402 in an axial direction A and is formed inwardly in a radial direction R of the first support member 410 and the second support member 420.

[0056] In various embodiments, the plurality of first support members 410 and the second support members 420 are alternately arranged along the circumferential direction C. In some embodiments, the bearing system 400 includes three or more first support members 410. In some embodiments, the bearing system 400 includes three or more second support members 420. Fig. 9 A side view of the bearing system 400 is provided, with the first support member 410 and the second support member 420 adjacent to each other along the axial direction A. Figure 8 and Fig. 9 , the plurality of first support members 410 and the second support members 420 are each alternately arranged along the circumferential direction C and deviate from each other along the axial direction A.

[0057] Reference Fig. 9 , and in Fig.11As further described in the embodiment of the present invention, the first support member 410 includes a first axial support arm 412 extending in the axial direction A and a first radial support arm 418 extending in the radial direction R. The first radial support arm 418 positions the bearing element 414 to contact the bearing surface 52 at the rotor 50. In some embodiments, the bearing surface 52 is a bearing race configured to be specifically for receiving contact with the bearing element 414. In certain embodiments, the bearing surface 52 is an inner bearing race that can be separated from the rotor 50. The first shell 416 surrounds the bearing element 414 so as to substantially constrain the bearing element 414 in the axial direction A, the circumferential direction C, or both. The first shell 416 and the bearing surface 52 together can accommodate or contain the bearing element 414. The bearing system can be connected to the rotor 50 by connecting the bearing surface 52 to the rotor 50.

[0058] In some embodiments, when the rotor 50 is in a static condition (e.g., not rotating, not during rotor operation), the first radial support arm 418 extends at an angle of approximately 90 degrees from the first axial support arm 412. In a particular embodiment, the first radial support arm 418 extends from a distal end of the first axial support arm 412 relative to the body 402.

[0059] In certain embodiments of the bearing system 400, each bearing element 414 is constrained by a respective first shell 416. In various embodiments, each first support member 410 is secured to the body 402 and is separated or isolated from direct contact with other first support members 410 in the plurality of first support members.

[0060] In various embodiments, bearing element 414 is a rolling bearing element that includes one or more of a spherical ball bearing, a cylindrical roller bearing, a tapered roller bearing, a needle bearing, or other suitable rolling elements configured to receive and transmit loads from rotor 50 .

[0061] A first channel 415 is formed in the first support member 410 to provide a first fluid flow 417 to the first cavity 405. The first cavity 405 is formed in the first shell 416. In addition, the first cavity 405 is formed between the bearing element 414 and the first shell 416. In various embodiments, as Fig. 9 and Fig.11 As described, the first channel 415 is formed in the first radial support arm 418 of the first support member 410. In some embodiments, for example, Fig. 9 As described in , the first channel 415 is further formed in the first axial support arm 412 of the first support member 410.

[0062] Still reference Fig. 9 , and further in Fig.13, the second support member 420 includes a second axial support arm 422 extending in the axial direction A and a second radial support arm 428 extending in the radial direction R. The second radial support arm 428 is operably arranged to position the second shell 426 close to the rotor 50. In various embodiments, each second support member 420 is fixed to the body 402.

[0063] A second channel 425 is formed in the second support member 420 to provide a second fluid flow 427 to the second cavity 435. The second cavity 435 is formed in the second shell 426. In addition, the second cavity 435 is formed at the second shell 426 and is directly adjacent to or near the bearing surface 52 of the rotor 50. In various embodiments, for example, Fig. 9 and Fig.13 As depicted in FIG. 4 , the second channel 425 is formed in the second radial support arm 428 of the second support member 420. In particular, the operative arrangement of the second shell 426 adjacent to the rotor 50 forms a static pressure or fluid film bearing at the cavity 435 between the second shell 426 and the rotor 50. In certain embodiments, for example, Figure 8 As described in the above, the plurality of second support members 420 are coupled to each other via the second shell 426 extending in the circumferential direction C to, for example, surround the rotor 50. In some embodiments, the second cavity 435 is an annular channel formed between the second shell 426 extending in annularly in the circumferential direction C and the rotor 50.

[0064] In some embodiments, when the rotor 50 is in a static condition (e.g., not rotating, not during rotor operation), the second radial support arm 428 extends at an angle of approximately 90 degrees from the second axial support arm 422. In a particular embodiment, the second radial support arm 428 extends from a distal end of the second axial support arm 422 relative to the body 402.

[0065] As mentioned above about Figure 8 or Fig. 9 , the plurality of first support members 410 and the plurality of second support members 420 are each positioned or formed to be adjacently arranged along the circumferential direction C, the axial direction A, or both. Fig. 9 The embodiment in further depicts a first shell 416 that is positioned away from the body 402 along the axial direction A relative to a second shell 426 that is positioned close to the body 402 along the axial direction A.

[0066] During operation of the bearing system 400, such as during loading and operation of the rotor 50, the first support members 410 can each act as a spring support with the bearing element 414 to provide improved load distribution between the bearing system 400 and the rotor 50. The first axial support arm 412, the first radial support arm 418, and the first shell 416 that are separated from the circumferentially adjacent first support members 410 can collectively allow for improved load distribution, improved deflection of the bearing element 414, or minimized ovalization of the bearing system 400. The independent first support members 410 can each act as a spring support to allow the bearing element 414 to remain in contact with the rotor 50. In certain embodiments, the first support members 410 are pre-strained spring beams that allow the bearing element 414 to be placed in desired contact with the rotor 50.

[0067] The substantially independent second support member 420 can achieve similar benefits as the first support member 410. The second support member 420, such as having an annularly extending second shell 426 surrounding the rotor 50 and forming a fluid bearing at the second cavity 435, can further provide improved damping relative to the configuration of the first support member 410. The plurality of second support members 420 can further generate less heat than the plurality of first support members 410. In addition, the plurality of second support members 420 can further allow for higher load capacity relative to the plurality of first support members 410.

[0068] Independent first support members 410 may allow for variable or circumferentially localized stiffness, allowing for improved load distribution, uniform load distribution, and bending or pitch buckling relative to the plurality of second support members 420. First support members 410 may particularly provide improved dynamic response and load distribution relative to high rotor imbalance, rotor bowing (e.g., bowed rotor start-up), or events during operation that may induce high rotor imbalance (e.g., rotor blade shedding, rotor blade release or other blade damage, internal or foreign object debris ingestion, ice ingestion, or damping system failure).

[0069] Brief reference Fig.10 , an embodiment of a bearing system 600 is provided, which includes a plurality of first support members 410, such as in Figure 8 and Fig. 9 The description of bearing system 400 in FIG. Bearing system 600 is configured substantially similarly to bearing system 400 in terms of the plurality of first support members 410 and bearing elements 414. Fig.11 Provided Fig.10 4 is a side cross-sectional view of the first support member 410, the body 402, and the rotor 50 at section 11-11 in FIG. Fig.11 The embodiments provided in the embodiment can be basically constructed as follows Fig. 9 as described in and as described in this article.

[0070] Brief reference Fig.12 , an embodiment of a bearing system 800 is provided, which includes a plurality of second support members 420, such as Figure 8 and Fig. 9 Bearing system 800 is configured substantially similarly to bearing system 400 in terms of second support member 420 and the fluid bearing formed by second shell 426. Fig.13 Provided Fig.12 Side cross-sectional view of the second support member 420 , the body 402 , and the rotor 50 at section 13 - 13 . Fig.13 The embodiments provided in the embodiment can be basically constructed as follows Fig. 9 as described in and as described in this article.

[0071] The bearing system 600 including the plurality of first support members 410 may be particularly advantageous for lower speed or lower load operating conditions relative to the bearing system 800 including the plurality of second support members 420. In addition, the bearing system 800 may be particularly advantageous for higher speed or higher load operating conditions relative to the bearing system 600. Figure 8 and Fig. 9 , an embodiment of the bearing system 400 is configured to position the first support member 410 for a first engagement corresponding to a low speed or low load operating condition (e.g., initial startup or drive, ignition, idle operating condition, partial load condition, etc.) relative to the second support member 420, and the second support member 420 is configured for a second engagement corresponding to a high speed or high load operating condition (e.g., maximum or full load condition, takeoff or cruise condition, etc.).

[0072] Reference now Fig.14 and Fig.15 , an exemplary schematic embodiment describing the loading of a plurality of independent first support members 410 is provided. The configuration of the first support member 410 and the Figure 8 , Fig. 9 , Fig.10 and Fig.11 The schematic diagram depicts a plurality of independent first support members that allow flexion in bending or pitching while providing stiffness in the radial direction R. In certain embodiments, as Fig.14 As depicted, one or more first support members 410 may include cylindrical rolling bearing elements 414, for example, particularly for loads in the radial direction R, and one or more first support members 410 may include ball or spherical rolling bearing elements 414, for example, particularly for loads in the radial direction R, the axial direction A, and moments in the tangential direction. In another embodiment, as Fig.15As depicted, the first support member 410 may be configured to receive dual bearing elements, such as a pair of balls or spherical rolling bearing elements, or a combination of rolling bearing elements provided herein, within a single corresponding first shell 416 .

[0073] The first fluid flow 417 ( Fig. 9 , Fig.11 ) may include any fluid suitable for operating rolling bearing elements. Particular embodiments define the first fluid stream 417 as air, such as pressurized compressor discharge air, such as downstream of a high pressure compressor (e.g., station 3), or between a high pressure compressor and a low or intermediate pressure compressor (e.g., station 2.5), or compressed air discharged from one or more stages of a compressor section, or other suitable compressed fluid sources.

[0074] The second fluid flow 427 ( Fig. 9 , Fig.13 ) may include any fluid suitable for operating a static pressure or fluid bearing. Certain embodiments define the second fluid stream 427 as one or more sources of air, such as the source of the first fluid stream 417. The first fluid stream 417 and the second fluid stream 427 may be co-sourced and separated to be provided to the respective first support member 410 and the second support member 420 (e.g., Figure 8 , Fig. 9 In other embodiments, the second fluid flow 427 is a lubricant, a hydraulic fluid, or other suitable fluid dynamic fluid for generating a fluid bearing at the second cavity 435 .

[0075] In various embodiments, the first support member 410 is formed of a first material that is different from the second material that forms the second support member 420. The first material and the second material may include a combination of shape memory alloys; metals, ceramics, or polymer-based composites; or metals and their alloys. The bearing system provided herein allows variable stiffness control to be achieved via different first and second materials, different flow conditions of fluids 417, 427, or a combination thereof. In one embodiment, the fluid streams 417, 427 defining a common temperature may affect the stiffness at the first support member formed by the first material, and the stiffness at the first support member is different from the stiffness of the second support member formed by the second material. In another embodiment, the first support member and the second support member provide different stiffness via different temperatures of the separated fluid streams through the respective support members. The stiffness or moment load along the axial direction A, the circumferential direction C may be changed at different locations via independent connection of the flow conditions (such as temperature, pressure, flow rate, etc.) of the fluid streams through the respective support members.

[0076] It should be understood that Figure 8-15 The rotor 50 depicted in FIG. 5 may include Figure 4-6 The high speed shaft 22 or drive shaft 29 of the engine 10 depicted in FIG. 1 , the first rotor assembly 110 of the interleaved turbine rotor assembly, Figure 3 The compressor 23 at the staggered compressor rotor assembly in Figure 1-3 1034 of the wind turbine 1000, or the rotor blades 1022 and pitch adjustment mechanism of the wind turbine 1000. Various embodiments of the rotor 50 may include a rotatable drum or shroud of the interleaved compressor section 21 or the interleaved turbine section 33, a fan shaft, or other rotatable shaft, drum, or rotor of a turbine, wind turbine, or other turbine system.

[0077] The embodiments of the bearing system provided herein are constructed as independent rolling bearing elements, allowing adaptive stiffness. The independent support arm configured as a spring member is integrated with the bearing element to allow local movement, adjustment or other compliance, allowing improved load distribution and mitigating the ovalization of the bearing system, rotor or shaft. The independent support arm allows the independent rolling bearing element to maintain constant or substantially constant contact with the rotor or shaft. The independent support arm may further include a shape memory alloy to provide improved damping and stiffness adaptability. In addition, the independent support arm can be circumferentially varied, for example, arranged in different or asymmetric circumferential arrangements. The embodiments of the bearing system provided herein allow improved rotor dynamic response, improved rotor stability, and improved adaptability to misalignment of the bearing and the rotor, for example, via the non-axisymmetric and / or non-uniform stiffness of a plurality of independent bearing support arms.

[0078] Embodiments of the bearing systems provided herein may provide benefits particularly for wind turbines as provided herein. Known pitch bearings are often susceptible to failure under high moment loads. The relatively low speed operation and relatively limited pitch of wind turbines may result in high loads, which may result in failure of known pitch bearings. Embodiments of the bearing systems provided herein may provide benefits particularly for gas turbine engine fan pitch control mechanisms, as described with respect to wind turbine pitch control.

[0079] Embodiments of the bearing systems provided herein may provide benefits specifically for gas turbine engines as provided herein. The bearing system may be positioned as described herein at one or more bearing locations, as known in the art on a two-spool or three-spool gas turbine engine. The bearing system may provide benefits specifically for staggered gas turbine engines, such as at an outer diameter bearing of a rotatable outer drum or outer shroud of a compressor section or turbine section. Embodiments of the bearing systems provided herein may provide benefits such as mitigation of rotation, undesirable rotor dynamics, unbalance, or other rotor dynamics or stability issues characteristic of staggered rotor structures, such as counter-rotating turbine or compressor rotors, prop fans, or open rotor structures, or generally large diameter rotor drums having airfoils extending radially inward.

[0080] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

[0081] Further content of the present invention is provided by the subject matter of the following clauses:

[0082] 1. A bearing system, the bearing system being configured to surround a rotor along a circumferential direction corresponding to the rotor, wherein the rotor extends along an axial direction which is the same direction as the centerline axis of the rotor, the bearing system comprising: a body, a plurality of first support members each extending from the body, and wherein the plurality of first support members are spaced apart from each other along the circumferential direction; wherein each first support member comprises a first axial support arm extending along the axial direction and a first radial support arm extending from the first axial support arm in a radial direction, and wherein the first radial support arm is configured to position a bearing element to contact a bearing surface at the rotor.

[0083] 2. A bearing system according to any clause herein, wherein the first axial support arm extends from the body, and wherein the first radial support arm extends from a distal end of the first axial support arm away from the body along the axial direction.

[0084] 3. The bearing system of any clause herein, wherein when the rotor is in a static condition, the first radial support arm extends from the first axial support arm at an angle of approximately 90 degrees.

[0085] 4. A bearing system according to any clause herein, wherein each first support member comprises a first shell connected to the first radial support arm, wherein the first support member is configured to position the bearing element in operable contact with the first shell and the bearing surface at the rotor.

[0086] 5. The bearing system according to any clause herein, wherein a first cavity is formed between the first shell and the bearing element.

[0087] 6. The bearing system of any clause herein, wherein a first channel is formed in the first support member, and wherein the first channel is in fluid communication with the first cavity.

[0088] 7. A bearing system according to any clause herein, wherein the first shell at each respective first support member is separate from each other.

[0089] 8. A bearing system according to any clause herein, comprising: a plurality of second support members, each of which extends from the body, wherein each second support member is positioned to be alternately arranged with the plurality of first support members along the circumferential direction.

[0090] 9. A bearing system according to any clause of the present invention, wherein each second support member comprises: a second axial support arm, the second axial support arm extending along the axial direction; and a second radial support arm, the second radial support arm extending from the second axial support arm along the radial direction toward the rotor.

[0091] 10. A bearing system according to any clause herein, wherein a second shell is connected to the second radial support arm, wherein the second radial support arm is operably arranged to position the second shell proximate to the rotor to form a fluid film bearing between the second shell and the rotor.

[0092] 11. A bearing system according to any clause herein, wherein the second support member positions the second shell to form a second cavity between the second shell and the rotor, and wherein a second channel is formed in the second support member in fluid communication with the second cavity.

[0093] 12. A bearing system according to any clause herein, wherein the second axial support arm positions the second shell close to the body along the axial direction relative to the first shell at the first support member.

[0094] 13. A bearing system according to any clause herein, wherein the second shell extends in the circumferential direction to surround the rotor, and wherein the second shell is connected to the second radial support arm at each second support member of the plurality of second support members.

[0095] 14. A bearing system according to any clause herein, wherein the first support member comprises a first material, and wherein the second support member comprises a second material different from the first material.

[0096] 15. A bearing system according to any clause herein, wherein the first material and the second material comprise shape memory alloys, metal matrix composites, ceramic matrix composites, polymer matrix composites, metals, metal alloys, or combinations thereof.

[0097] 16. A bearing system according to any clause herein, wherein the bearing element is one or more of a spherical ball bearing, a cylindrical roller bearing, a tapered roller bearing, a needle bearing, or a combination thereof.

[0098] 17. A bearing system according to any clause herein, wherein each first support member comprises a first shell connected to the first radial support arm, wherein the first support member is configured to position the bearing element in operable contact with the bearing surface at the first shell and the rotor, and wherein each first shell is configured to receive a pair of bearing elements.

[0099] 18. A bearing system according to any clause herein, wherein the bearing surface is an inner bearing race extending along the circumferential direction.

[0100] 19. A gas turbine engine, the gas turbine engine comprising: a fan assembly, wherein the fan assembly comprises a plurality of fan blades and a bucket assembly, wherein the bucket assembly or one or both of the plurality of fan blades are adjustable along a corresponding pitch axis; a core engine, the core engine being configured to drive the plurality of fan blades of the fan assembly; and a bearing system, the bearing system being positioned at one or more of the core engine, the plurality of fan blades or the bucket assembly, wherein the bearing system is configured to surround a rotor at the core engine or the fan assembly along a circumferential direction corresponding to the rotor, wherein the rotor extends along an axial direction that is synch with a centerline axis of the rotor, wherein the bearing system comprises a body, a plurality of first support members each extending from the body, and wherein the plurality of first support members are spaced apart from each other along the circumferential direction, and wherein each first support member comprises a first axial support arm extending along the axial direction and a first radial support arm extending from the first axial support arm in a radial direction, and wherein the first radial support arm is configured to position a bearing element to contact a bearing surface at the rotor.

[0101] 20. A wind turbine, the wind turbine comprising: a tower extending from a support surface; a nacelle mounted to the tower; a rotor coupled to the nacelle, wherein the rotor comprises a rotatable hub and rotor blades coupled to the hub; and a bearing system positioned at one or more of the rotor or the rotor blades, wherein the bearing system is configured to surround the rotor along a circumferential direction corresponding to the rotor, wherein the rotor extends along an axial direction that is synch with a centerline axis of the rotor, wherein the bearing system comprises a body, a plurality of first support members each extending from the body, and wherein the plurality of first support members are spaced apart from each other along the circumferential direction, and wherein each first support member comprises a first axial support arm extending along the axial direction and a first radial support arm extending from the first axial support arm in a radial direction, and wherein the first radial support arm is configured to position a bearing element to contact a bearing surface at the rotor.

Claims

1. A bearing system, characterized in that: The bearing system is configured to surround the rotor in a circumferential direction corresponding to the rotor, wherein the rotor extends in an axial direction that is the same direction as the centerline axis of the rotor, and the bearing system comprises: ontology; a plurality of first support members; and a plurality of first shells; wherein each of the plurality of first support members extends from the body to a corresponding one of the plurality of first shells, wherein the plurality of first support members are spaced apart from one another along the circumferential direction, wherein the plurality of first shells are spaced apart from one another along the circumferential direction, Each of the plurality of first support members comprises: a first axial support arm extending from the body in the axial direction; and a first radial support arm extending from the first axial support arm in a radial direction toward the centerline axis, and Each first shell of the plurality of first shells includes a bearing element, wherein each bearing element is configured to contact a bearing surface at the rotor.

2. The bearing system according to claim 1, characterized in that: The first radial support arm of each first support member in the plurality of first support members is aligned with a corresponding first shell in the plurality of first shells in the radial direction.

3. The bearing system according to claim 2, characterized in that: Wherein for each first support member, when the rotor is in a static condition, the first radial support arm extends from the first axial support arm at an angle of 90 degrees relative to the first axial support arm.

4. The bearing system according to claim 1, characterized in that: Each first shell of the plurality of first shells includes a first cavity configured to receive the bearing element.

5. The bearing system according to claim 4, characterized in that: Each of the plurality of first support members includes a first channel in fluid communication with the first cavity of a corresponding one of the plurality of first shells.

6. The bearing system according to claim 1, characterized in that: include: a plurality of second support members and a plurality of second shells, wherein each of the plurality of second support members extends from the body to a corresponding second shell of the plurality of second shells, wherein the plurality of second support members are positioned to be alternately arranged with the plurality of first support members along the circumferential direction, and wherein the plurality of second shells are positioned to be alternately arranged with the plurality of first shells along the circumferential direction.

7. The bearing system according to claim 6, characterized in that Each second support member comprises: a second axial support arm, the second axial support arm extending along the axial direction; A second radial support arm extends from the second axial support arm toward the rotor in the radial direction.

8. The bearing system according to claim 7, characterized in that Each of the plurality of second support members is operatively arranged to position a corresponding one of the plurality of second shells proximate to the rotor to form a fluid film bearing between the corresponding one of the plurality of second shells and the rotor.

9. The bearing system according to claim 8, characterized in that wherein each of the plurality of second support members positions a corresponding one of the plurality of second shells to form a second cavity between the corresponding one of the plurality of second shells and the rotor, and wherein a second channel is formed in each of the plurality of second support members to be fluidically connected to the second cavity of the corresponding one of the plurality of second shells.

10. The bearing system according to claim 8, characterized in that Wherein a first first shell among the plurality of first shells and a first second shell among the plurality of second shells are aligned along the axial direction.

11. The bearing system according to claim 1, characterized in that: include a plurality of second support members; and A second shell extends in the circumferential direction to surround the rotor, wherein the second shell is connected to the plurality of second support members.

12. The bearing system according to claim 7, characterized in that Wherein at least one first support member of the plurality of first support members comprises a first material, and wherein at least one second support member of the plurality of second support members comprises a second material different from the first material.

13. The bearing system according to claim 12, characterized in that The first material and the second material include at least one of shape memory alloys, metal-based composite materials, ceramic-based composite materials, polymer-based composite materials, metals and metal alloys.

14. The bearing system according to claim 1, characterized in that Each bearing element is at least one of a spherical ball bearing, a cylindrical roller bearing, a tapered roller bearing and a needle roller bearing.

15. The bearing system according to claim 14, characterized in that At least one first shell of the plurality of first shells comprises at least two bearing elements.

16. The bearing system according to claim 1, characterized in that Wherein the bearing surface is an inner bearing race extending along the circumferential direction.

17. A gas turbine engine, characterized in that: The gas turbine engine comprises: a fan assembly, wherein the fan assembly includes a plurality of fan blades and a vane assembly; a core engine configured to drive the plurality of fan blades of the fan assembly; and a bearing system positioned at one or more of the core engine, the plurality of fan blades, and the bucket assembly, wherein the bearing system is configured to surround a rotor of at least one of the core engine and the fan assembly in a circumferential direction corresponding to the rotor, wherein the rotor extends in an axial direction that is coinciding with a centerline axis of the rotor, wherein the bearing system comprises: ontology; a plurality of first support members; and a plurality of first shells, wherein each of the plurality of first support members extends from the body to a corresponding one of the plurality of first shells, wherein the plurality of first support members are spaced apart from one another along the circumferential direction, wherein the plurality of first shells are spaced apart from one another along the circumferential direction; Each of the first support members comprises: a first axial support arm extending along said axial direction; and a first radial support arm extending in a radial direction from the first axial support arm; and Each of the plurality of first shells includes a bearing element that contacts a bearing surface at the rotor.

18. A wind turbine, characterized in that: The wind turbine comprises: a tower extending from a support surface; a nacelle mounted to the tower; a rotor coupled to the nacelle, wherein the rotor comprises a rotatable hub and rotor blades coupled to the hub; and a bearing system positioned at one or more of the rotor and the rotor blades, wherein the bearing system is configured to surround the rotor in a circumferential direction corresponding to the rotor, wherein the rotor extends in an axial direction that is coinciding with a centerline axis of the rotor, wherein the bearing system comprises: ontology; a plurality of first support members; and a plurality of first shells, wherein each of the plurality of first support members extends from the body to a corresponding one of the plurality of first shells, wherein the plurality of first support members are spaced apart from one another along the circumferential direction, wherein the plurality of first shells are spaced apart from one another along the circumferential direction; Each of the first support members comprises: a first axial support arm extending along said axial direction; and a first radial support arm extending in a radial direction from the first axial support arm; and Each of the plurality of first shells includes a bearing element that contacts a bearing surface at the rotor.

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