Compliant Journal Bearings for Planetary Gearbox Load Distribution

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Solution Overview

Problem

Conventional aircraft engine gearboxes face issues with load concentration at the extremities of bearings due to increased length, leading to potential lubrication film failure and distress under torque, which affects the durability and efficiency of the gearbox.

Innovation Solution

A planetary gear train design with a sun gear, planet gear assemblies, journal bearings, and a lubrication system that includes undercuts in the journal bearings to enhance compliance and distribute loads symmetrically, reducing the risk of lubrication film failure and improving torque handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the bearing length is increased to increase power to weight ratio, then the power to weight ratio is improved, but the load concentrates on the extremities of the bearings causing lubrication film failure

Engineering Contradiction:
Improvepower to weight ratioVSAvoidlubrication film stability
Core Design Contradiction:
PowerVSReliability

Solution Approach 1:

The bearing geometry is modified by introducing undercuts at the extremities, creating non-uniform local properties. The undercut regions have reduced material thickness compared to the mid-section, which redistributes the load more evenly along the bearing length and prevents concentration at the ends, thereby maintaining lubrication film stability while allowing increased bearing length for higher power density

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The bearing cross-sectional geometry parameter is changed by introducing undercuts, transforming the uniform cylindrical shape into a non-uniform profile. This parameter change modifies the stress distribution along the bearing, reducing peak stresses at the extremities and preventing lubrication film failure while enabling longer bearing lengths for improved power to weight ratio

Inventive Principle:
Principle #35Parameter changes

2Force

If the bearing length is increased to handle higher torques, then the torque capacity is improved, but the load concentration causes bearing distress

Engineering Contradiction:
Improvetorque capacityVSAvoidbearing distress resistance
Core Design Contradiction:
ForceVSStrength

Solution Approach 1:

The bearing is designed with localized geometric variations (undercuts) at the extremities, creating regions with different structural properties. This local modification redistributes the torque-induced load more uniformly along the bearing length, preventing the load concentration that would otherwise cause bearing distress while maintaining the increased length needed for higher torque capacity

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The undercut geometry acts as a pre-designed stress-relief feature that cushions against the concentration of loads at the bearing extremities. By incorporating these geometric features in advance, the bearing is prepared to handle high torque loads without experiencing distress from load concentration at the ends

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The design achieves improved load distribution and compliance, allowing the gearbox to withstand higher torques and maintain lubrication effectiveness, enhancing the durability and efficiency of the aircraft engine gearbox.

Implementation Method 1

a lubrication system extending within the planet carrier and hydraulically connected to the gaps between the journal bearings and the planet gear assemblies

Methodology Applied
Scientific EffectHydraulic connection: Hydraulic Press

Implementation Method 2

journal bearings rotatably supporting the planet gear assemblies for rotation about rotation axes

Methodology Applied
Scientific EffectLubrication: Lubrication

Data Source

PatentUS11300007B2Planetary gearbox having compliant journal bearings
Publication Date: 2022.04.12 PRATT & WHITNEY CANADA CORP
  • US11300007B2 patent drawing
  • US11300007B2 patent drawing
  • US11300007B2 patent drawing

AI summary

A planetary gear train for an aircraft engine, has: a sun gear; planet gear assemblies having main gears meshed with the sun gear, fore lateral gears and aft lateral gears disposed on opposite sides of the main gears and rotating therewith; journal bearings rotatably supporting the planet gear assemblies for rotation about rotation axes, gaps defined between the journal bearings and the planetary gear assemblies; a planet carrier supporting the journal bearings; a fore ring gear meshed with the fore lateral gears; an aft ring gear meshed with the aft lateral gears; and a lubrication system extending within the planet carrier and hydraulically connected to the gaps between the journal bearings and the planet gear assemblies.