Bearing Carrier Support Using Dense Struts for Shorter Engine Packaging
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Solution Overview
Problem
Current bearing carrier supports for gas turbine engines are lengthy and heavy, contributing to increased specific fuel consumption and cost due to the need for long, slender spring bars that balance radial and axial stiffness requirements, while also being expensive to manufacture and assemble.
Innovation Solution
A bearing carrier support with a plurality of circumferentially distributed struts, axially aligned with the rotary shaft, where the number of struts is at least 500 and their diameter is no more than 3 mm, made from materials like steel, titanium, or composite reinforced rods, which are welded, bonded, or trapped between the flange and bearing portions, allowing for reduced weight and axial length through Additive Layer Manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If long slender spring bars are used to balance radial and axial stiffness requirements, then the desired stiffness targets are achieved, but the component length and weight increase
Solution Approach 1:
The support structure is segmented into multiple discrete struts (at least 500 struts with diameter no more than 3mm) arranged circumferentially between the flange and bearing portions. This segmentation allows the load to be distributed across many small elements rather than requiring long continuous bars, achieving the desired stiffness through collective structural behavior while maintaining compact length
Solution Approach 2:
The invention changes the structural parameters from few long bars to many short struts. By increasing the number of load-bearing elements from a small number to at least 500, and reducing individual element diameter to no more than 3mm, the collective axial stiffness is maintained or enhanced while the component length is significantly reduced
2Strength
If long slender spring bars are used to balance radial and axial stiffness requirements, then the desired stiffness targets are achieved, but the component weight increases
Solution Approach 1:
The support structure is segmented into multiple discrete struts (at least 500 struts with diameter no more than 3mm) arranged circumferentially between the flange and bearing portions. This segmentation allows the load to be distributed across many small elements rather than requiring long continuous bars, achieving the desired stiffness through collective structural behavior while maintaining compact length
Solution Approach 2:
The invention changes the structural parameters from few long bars to many short struts. By increasing the number of load-bearing elements from a small number to at least 500, and reducing individual element diameter to no more than 3mm, the collective axial stiffness is maintained or enhanced while the component length is significantly reduced
3Strength
If traditional bearing carrier supports are used, then the stiffness requirements are met, but the engine centreline length and packaging efficiency deteriorate
Solution Approach 1:
The support structure is segmented into multiple discrete struts (at least 500 struts with diameter no more than 3mm) arranged circumferentially between the flange and bearing portions. This segmentation allows the load to be distributed across many small elements rather than requiring long continuous bars, achieving the desired stiffness through collective structural behavior while maintaining compact length
Solution Approach 2:
The invention transitions from a one-dimensional long bar structure to a three-dimensional distributed strut array. By arranging at least 500 struts circumferentially between the flange and bearing portions, the load-bearing function is achieved through spatial distribution in multiple dimensions, enabling compact axial length while maintaining structural integrity
Data Source
Figure 1~2
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AI summary
A bearing carrier support (50) for connecting a rotary shaft of a gas turbine engine (10) to a static portion of the gas turbine engine. The bearing carrier support has: a bearing portion (60) for supporting the rotary shaft; a flange portion (70) for attaching the bearing carrier support to the static portion of the gas turbine engine; and a support portion (80) that connects the flange portion and the bearing portion. The support portion (80) has a plurality of circumferentially distributed struts (110) that are axially aligned with respect to the rotary shaft. The number of struts (110) is at least 500 and the diameter of each strut is no more than 3 mm.