Journal Foil Bearing Top Foil Insert for Load and Lift-Off Control
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Solution Overview
Problem
Conventional foil bearing systems face challenges in controlling bearing support loads, lift-off speed, and manufacturing efficiency, due to difficulties in controlling component dimensions and high part counts.
Innovation Solution
The foil bearing system incorporates a journal member with a bore and internal groove, featuring a shaft supported by a foil arrangement including biasing foils and a top foil insert member with a spine insert. This configuration allows for precise control of bearing characteristics and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional foil bearing systems use traditional foil structures, then the bearing can support shaft rotation, but it is difficult to precisely control bearing support loads and lift-off speed
Solution Approach 1:
The top foil is divided into multiple segments (first top foil segment, second top foil segment, third top foil segment) with different stiffness characteristics. Each segment can be independently designed and controlled, allowing precise adjustment of bearing support loads and lift-off speed while simplifying manufacturing by using standardized segment components.
Solution Approach 2:
The bearing system combines foils with different material properties and stiffness characteristics (first, second, and third foils with varying rigidity) to create a composite structure. This allows precise control of bearing characteristics through material selection while maintaining manufacturing efficiency through standardized foil production processes.
2Productivity
If conventional foil bearing systems use multiple separate components, then the bearing can provide necessary support functions, but manufacturing and assembly become labor and energy intensive
Solution Approach 1:
The first top foil segment, second top foil segment, and third top foil segment are combined into a single integrated top foil assembly that functions as one unit during assembly. This reduces the number of separate assembly steps while maintaining the ability to control bearing characteristics through the segmented foil design.
Solution Approach 2:
The journal member is designed with universal features including an internal groove that accommodates the entire foil arrangement, allowing the same basic component structure to support different bearing configurations. This standardization improves manufacturing efficiency while maintaining functional versatility.
3Reliability
If conventional foil bearing systems use complex component dimensions, then the bearing can achieve desired performance characteristics, but costs increase and handling becomes more difficult
Solution Approach 1:
Different portions of the top foil assembly have different stiffness characteristics (first, second, and third segments with varying rigidity) tailored to specific local requirements. This allows optimal bearing performance in critical areas while using simpler, more cost-effective designs in less critical areas, reducing overall manufacturing complexity and cost.
Solution Approach 2:
The bearing system controls performance characteristics by changing physical parameters of the foil segments (thickness, width, material properties) rather than complex geometric configurations. This allows precise control of bearing support loads and lift-off speed through simple parameter adjustments that are easier and less costly to manufacture.
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 system achieves precise control over bearing loads and lift-off speed, while reducing manufacturing complexity and costs, thereby enhancing the overall efficiency and performance of the foil bearing system.
Implementation Method 1
The at least one biasing foil is received between the journal member and the shaft in a radial direction with respect to the axis
Data Source
AI summary
A foil bearing system includes a journal member with an internal groove and a foil arrangement. The foil arrangement includes at least one biasing foil and a top foil insert member. The at least one biasing foil is received between the journal member and the shaft in a radial direction with respect to the axis. The top foil insert member includes a top foil and a spine insert. The top foil includes an arcuate portion that is disposed between the at least one biasing foil and the shaft in the radial direction and that extends in a circumferential direction about the axis. The top foil includes an end that extends from the arcuate portion. The spine insert is received within the internal groove, and the spine insert is fixedly attached to the end of the top foil.