Reduced-Weight Bearing Pins Using Internal Voids

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Solution Overview

Problem

Known bearing pins in epicyclic gear assemblies are heavy due to unnecessary internal material, which reduces the efficiency of these assemblies without significantly enhancing their strength.

Innovation Solution

A method and design for bearing pins with varying densities, where less dense regions are introduced within the pin structure to reduce weight while maintaining strength, using techniques like additive manufacturing and reinforcement with lattice structures or metal foams, and simulating operational loads to identify and remove material without compromising structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If bearing pins are formed from solid bar stock or billets, then the structural strength is maintained, but the weight increases with unnecessary internal material

Engineering Contradiction:

Improvestructural strengthVSAvoidbearing pin weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The bearing pin incorporates internal voids or porous structures within its body, creating regions of reduced material density. This allows the pin to maintain sufficient structural strength for load-bearing functions while significantly reducing the overall weight by eliminating unnecessary internal material that does not contribute to strength.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The bearing pin uses composite construction with different material densities in different regions - solid or reinforced material in high-stress areas and voids or lower-density material in low-stress areas. This composite approach optimizes the strength-to-weight ratio by placing material only where structurally necessary.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If internal material is removed from bearing pins, then the weight is reduced, but the structural integrity may be compromised

Engineering Contradiction:

Improvebearing pin weightVSAvoidstructural integrity

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The bearing pin features non-uniform material distribution with varying density throughout its structure. High-density solid material is concentrated in regions experiencing high stress or requiring structural support, while low-density voids are placed in regions where material is not critical for strength. This local quality variation maintains structural integrity while minimizing weight.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The design process uses finite element analysis and stress simulation to identify critical stress regions before manufacturing. This preliminary analysis allows engineers to strategically place voids in low-stress areas and concentrate material in high-stress areas, ensuring structural integrity is maintained while achieving weight reduction.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10228024B2Reduced-weight bearing pins and methods of manufacturing such bearing pins

Publication Date: 2019.03.12 GENERAL ELECTRIC CO

AI summary

A method of designing and manufacturing a bearing pin having an external bearing pin geometry includes generating a first pin model conforming to the external bearing pin geometry. One or more operational loads to be applied to the bearing pin are then simulated on the first pin model to identifying at least one first internal region of the first pin model in which at least one of stress, strain, and displacement are below a first predetermined limit. The method further includes generating a final pin model based on the first pin model by forming a first void by removing the at least one first internal region from the first pin model. The bearing pin is then manufactured in accordance with the final pin model.