Double Splined Coupling With Crowned Splines for Engine Core Misalignment
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Solution Overview
Problem
Existing turbine engines face challenges in integrating an electric machine within the engine core, particularly in coupling rotating components like the electric machine or gearbox with the turbine engine shaft effectively.
Innovation Solution
A double splined coupler, such as a double articulation quill shaft, is used to connect rotating structures within the turbine engine, incorporating crowned spline connections to accommodate axial misalignment and operational shifts, and a flexible coupling for additional flexibility, along with a seal assembly to isolate compartments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electric machine is arranged within the engine core, then the overall size of the gas turbine engine is reduced, but the complexity of coupling rotating components increases
Solution Approach 1:
The double splined coupler is arranged within the engine core, nesting the electric machine coupling mechanism inside the existing turbine engine structure. This allows the electric machine to be integrated within the core rather than externally, reducing overall engine volume while maintaining functional coupling capabilities through the nested splined connection system
Solution Approach 2:
The coupler is divided into multiple segments including a first spline connection for connecting to the turbine engine shaft and a second spline connection for connecting to the electric machine. This segmentation allows each spline connection to be optimized independently for its specific coupling requirements, managing the complexity of integrating multiple rotating components within the constrained engine core space
2Adaptability or versatility
If crowned spline connections are used to accommodate axial misalignment, then the adaptability of the coupling increases, but the manufacturing precision requirements increase
Solution Approach 1:
The spline connections incorporate crowned surfaces with curved geometries rather than flat surfaces. This curvature allows the spline teeth to maintain contact and transmit torque even when axial misalignment occurs between the turbine engine shaft and the electric machine, providing adaptability to operational shifts while the precise crowning geometry ensures proper load distribution across the spline interface
3Reliability
If a flexible coupling is incorporated, then the reliability of the connection increases, but the device complexity increases
Solution Approach 1:
The coupler incorporates flexible elements that allow dynamic adjustment and movement to accommodate operational variations and misalignments between the turbine engine shaft and the electric machine. This flexibility enhances the reliability of the connection by allowing the coupling to adapt to changing operational conditions, while the flexible design is integrated into the overall coupler structure to manage complexity
Data Source
Figure 1
Figure 1B
Figure 2~3C
AI summary
An assembly is provided for a turbine engine. This turbine engine assembly includes a turbine engine shaft, a gearbox and a coupler. The turbine engine shaft is configured to rotate about a rotational axis. The gearbox includes a gear configured to rotate about the rotational axis. The coupler is coupled to the turbine engine shaft by a coupler-shaft connection. The coupler-shaft connection is configured as or otherwise includes a crowned spline connection. The coupler is coupled to the gear by a coupler-gear connection. The coupler-gear connection is configured as or otherwise includes a crowned spline connection.