Compliant Gear Baffle Structure for Gearbox Lubricant Churning

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Solution Overview

Problem

The design and installation of effective gear baffles in gas turbine engine gearboxes are challenging due to space constraints and dimensional variations, leading to undesirable lubricant fluid churning and energy losses.

Innovation Solution

A gear baffle with a compliant corrugation that accommodates variations in distance between attachment points, allowing non-destructive deformation to fit within the gearbox dimensions, thereby mitigating churning and ensuring effective interaction with lubricant fluid.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rigid gear baffle is installed in the gearbox, then the baffle can effectively mitigate lubricant fluid churning, but the baffle cannot accommodate dimensional variations in the gearbox

Engineering Contradiction:

Improvechurning mitigation effectivenessVSAvoidaccommodation of dimensional variations

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The gear baffle incorporates a corrugated structure that provides flexibility and compliance, allowing the baffle to deform and accommodate dimensional variations in the gearbox while maintaining its position and function. The corrugations act as flexible elements that can compress or expand to absorb dimensional changes.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The baffle design changes the physical parameter of rigidity by introducing corrugations that allow controlled deformation. This enables the baffle to transition from a completely rigid structure to one that has compliant characteristics, allowing it to adapt to dimensional variations while still providing effective churning mitigation.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If the distance between attachment points is fixed, then the baffle structure is simple and rigid, but it cannot accommodate variations in axial distance

Engineering Contradiction:

Improvebaffle structure simplicityVSAvoidaccommodation of axial distance variation

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The corrugated main wall acts as a flexible element that can deform axially to accommodate variations in distance between attachment points. This flexible structure maintains relative simplicity while providing the necessary adaptability to dimensional changes in the installation environment.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If a compliant corrugation is added to the baffle, then the baffle can accommodate dimensional variations, but the baffle structure becomes more complex

Engineering Contradiction:

Improveaccommodation of dimensional variationsVSAvoidbaffle structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The corrugated structure is formed as an integral part of the baffle, combining flexibility with structural integrity. This approach adds adaptability while minimizing overall complexity, as the corrugations are formed in a single piece rather than requiring multiple components or complex assemblies.

Inventive Principle:

Principle #30Flexible shells and thin films

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 compliant corrugation enables the gear baffle to effectively reduce lubricant fluid churning and accommodate dimensional variations, improving energy efficiency and installation flexibility within the gearbox.

Implementation Method 1

the main wall including a compliant corrugation that accommodates a variation in the distance between the first interface and the second interface

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS20220195945A1Gear baffle

Publication Date: 2022.06.23 PRATT & WHITNEY CANADA CORP

AI summary

A gear baffle, a gearbox of a gas turbine engine including a gear baffle, and a method of installing a gear baffle adjacent to a gear in a gearbox of a gas turbine engine are disclosed. The gearbox includes a housing, having disposed therein a gear, and a baffle adjacent to the gear to interact with lubricant fluid around the gear. The baffle includes a first interface for attaching the baffle to a structure to a first side of the gear, and a second interface for attaching the baffle to a structure to a second, axially opposite, side of the gear. The second interface may be axially spaced apart from the first interface by an axial distance. The baffle may include a main wall interconnecting the first interface with the second interface. The main wall may include a compliant corrugation that accommodates a variation in the axial distance between the first interface and the second interface.