Gear Assembly Support with Segmented Torque Path
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Solution Overview
Problem
Existing gear assembly supports for gas turbine engines face challenges in balancing cost, weight, and functional requirements while effectively transferring torque and maintaining optimal speeds for the fan and turbine sections.
Innovation Solution
A flexible gear assembly support with adjustable undercuts and a separate torque reacting portion, featuring a snap fit and flex design, allows for independent tuning of the interference fit and torque transmission path, enabling efficient torque transfer and orientation while minimizing material thickness for reduced weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the flexible support is designed with increased material thickness to improve structural strength and torque transfer capability, then the torque transfer function is improved, but the weight and manufacturing cost increase
Solution Approach 1:
The flexible support is divided into distinct functional segments: a snap portion for interference fit with the case, a torque portion for torque transfer, and a flex portion connecting them. This segmentation allows each segment to be optimized independently for its specific function, enabling thin-walled construction without compromising overall performance.
Solution Approach 2:
Different regions of the flexible support are given different local properties: the snap portion has features for secure attachment to the case, the torque portion has geometry optimized for torque transfer, and the flex portion has compliant characteristics. This local differentiation allows minimal material thickness while maintaining required functions in each region.
2Strength
If the flexible support is designed with increased material thickness to improve structural strength and torque transfer capability, then the torque transfer function is improved, but the manufacturing cost increases
Solution Approach 1:
The flexible support is divided into distinct functional segments: a snap portion for interference fit with the case, a torque portion for torque transfer, and a flex portion connecting them. This segmentation allows each segment to be optimized independently for its specific function, enabling thin-walled construction without compromising overall performance.
Solution Approach 2:
The design changes the geometric parameters of the flexible support, using thin-walled construction with strategically placed features (undercuts, flanges, grooves) to achieve required structural performance. This parameter optimization reduces material usage and manufacturing cost while maintaining torque transfer capability.
3Ease of manufacture
If the flexible support uses a simplified design to reduce cost and weight, then the manufacturing cost and weight are reduced, but the fit precision and torque transfer reliability deteriorate
Solution Approach 1:
The flexible support is divided into distinct functional segments: a snap portion for interference fit with the case, a torque portion for torque transfer, and a flex portion connecting them. This segmentation allows each segment to be optimized independently for its specific function, enabling thin-walled construction without compromising overall performance.
Solution Approach 2:
Different regions of the flexible support are given different local properties: the snap portion has features for secure attachment to the case, the torque portion has geometry optimized for torque transfer, and the flex portion has compliant characteristics. This local differentiation allows minimal material thickness while maintaining required functions in each region.
4Ease of manufacture
If the flexible support uses a simplified design to reduce weight and cost, then the manufacturing cost and weight are reduced, but the functional performance in balancing fit and torque transfer deteriorates
Solution Approach 1:
The flexible support is divided into distinct functional segments: a snap portion for interference fit with the case, a torque portion for torque transfer, and a flex portion connecting them. This segmentation allows each segment to be optimized independently for its specific function, enabling thin-walled construction without compromising overall performance.
Solution Approach 2:
The flexible support structure serves multiple functions simultaneously: the snap portion provides interference fit and orientation, the torque portion transfers torque, and the flex portion provides compliance. This multi-functionality is achieved in a single integrated component that balances all requirements.
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 flexible support structure enhances the balance between cost, weight, and performance by allowing independent adjustment of the interference fit and torque transmission, resulting in a more robust and efficient gear assembly support that optimizes engine efficiency and power density.
Implementation Method 1
a flex portion disposed between the second portion and the torque reacting portion
Data Source
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AI summary
A disclosed gear assembly support for a gas turbine engine includes a first portion configured for attachment to a case of the gas turbine engine and a second portion configured for supporting a gear assembly. The support further includes a snap portion defining a fit within the case. The snap portion includes a tunable feature for adjusting a fit within the case. A torque reacting portion of the support transfers torque from the second portion to the first portion separate from the snap portion and include separately tunable features fore adjusting the snap fit independent of the torque transfer portions.