Aircraft Gear Assembly Lubricant Reservoir for Emergency Flow
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Solution Overview
Problem
Turboshaft-powered aircraft face gear assembly failures due to lubricant flow issues, with existing solutions adding weight and reducing performance while being prone to system failures and lacking flexibility for mission adaptations.
Innovation Solution
A gear assembly design featuring a walled lubricant tank with a reservoir inlet adjacent to the gear mesh, a walled conduit for gravitational lubricant flow, and a lubricant dispensing device, allowing for emergency lubricant distribution without external connections, enabling modular and adaptable lubricant reservoir geometry via additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external auxiliary tanks are used to provide emergency lubricant flow, then emergency lubricant supply is ensured, but aircraft weight increases and performance decreases
Solution Approach 1:
The patent combines the emergency lubricant reservoir with the existing gearbox housing structure, eliminating the need for separate external auxiliary tanks. The reservoir is formed as an integrated cavity within the housing, sharing the same structural space and reducing overall system weight while maintaining emergency lubricant supply capability.
Solution Approach 2:
The gearbox housing serves multiple functions: it encloses the gear assembly, provides structural support, and simultaneously acts as a container for the emergency lubricant reservoir. This multi-functionality reduces the number of separate components needed, thereby reducing weight while ensuring emergency lubricant availability.
2Reliability
If internal auxiliary tanks are used to reduce external components, then component failure risk is reduced, but aircraft weight still increases
Solution Approach 1:
The emergency lubricant reservoir is merged with the gearbox housing structure, forming a single integrated component. This eliminates the weight penalty of separate internal auxiliary tanks while maintaining the reliability benefits of having the reservoir protected within the gearbox housing.
3Reliability
If internal auxiliary tanks are used, then external component failures are reduced, but tank replacement flexibility is lost
Solution Approach 1:
The lubricant delivery system is segmented into a permanent housing-integrated reservoir and a replaceable lubricant dispensing device. The dispensing device can be independently replaced or upgraded without affecting the reservoir, maintaining flexibility while keeping the reservoir protected within the housing.
4Reliability
If dedicated lubricant delivery systems are used, then emergency lubricant flow is ensured, but system complexity and weight increase
Solution Approach 1:
The emergency lubricant delivery system uses the existing gear meshing action to drive lubricant from the reservoir through dispensing devices. This eliminates the need for dedicated pumps, valves, and control systems, reducing complexity while ensuring reliable emergency lubricant flow through the gear mesh itself.
Solution Approach 2:
The gear assembly itself serves as the lubricant delivery mechanism during emergency conditions. The rotating gears automatically pump and distribute lubricant from the reservoir through the meshing action, eliminating the need for external dedicated delivery systems and their associated complexity.
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
This solution provides a flexible and lightweight emergency lubricant system that mitigates lubricant loss and system failures, reducing aircraft weight and improving performance by eliminating the need for pre-flight fill-ups and dedicated lubricant components, while ensuring continuous lubrication during normal and emergency operations.
Implementation Method 1
The walled conduit, the lubricant dispensing device, and the walled lubricant tank are coupled together to provide a flow of lubricant to the first gear or the second gear, or both, via gravitational force.
Implementation Method 2
A lubricant dispensing device is disposed at the in-mesh side of the gear mesh. The lubricant dispensing device is coupled in fluid communication with the walled conduit.
Data Source
AI summary
A gear assembly of an aircraft including an engine is generally provided. The gear assembly includes a first gear meshed with a second gear to define a gear mesh, and a walled lubricant tank defining a lubricant reservoir and a reservoir inlet opening. The reservoir inlet opening is defined adjacent to an out-of-mesh side of the gear mesh. At least a portion of lubricant from the gear mesh enters the lubricant reservoir through the reservoir inlet opening.