Gearbox Mounting Assembly With Flex Coupling for Dynamic Alignment
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Solution Overview
Problem
Existing gearbox assemblies in gas turbine engines experience misalignments and premature failure due to dynamic loading, leading to increased stress and degradation of components, particularly as engines increase in thrust and power.
Innovation Solution
A mounting assembly for the gearbox assembly that includes a flex coupling, flex mount, and fan frame, designed to manage lateral, bending, and torsional stiffness and damping properties, optimizing the support structure to handle varying flight conditions and reduce relative movements among gearbox components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid mounting structure is used for the gearbox assembly, then the gearbox is securely supported, but misalignments and stress increase under dynamic loading conditions
Solution Approach 1:
The mounting assembly transitions from a rigid static structure to a dynamic system with flex mounts and flex couplings that can adapt to varying flight conditions. The flex mounts allow controlled movement and compliance, enabling the gearbox to maintain proper alignment under dynamic loading while still providing secure support.
Solution Approach 2:
The invention changes the stiffness parameters of the mounting structure by introducing flexible elements with specific lateral, bending, and torsional stiffness characteristics. This allows the mounting assembly to provide sufficient support strength while accommodating dynamic movements and preventing misalignments that would compromise reliability.
2Power
If the engine thrust and power are increased, then the propulsion capability is improved, but the stress on gearbox components increases leading to premature failure
Solution Approach 1:
The flex mounts and flex couplings act as intermediary elements between the high-power turbine and the fan, absorbing and distributing the dynamic loads and stresses. These compliant mounting elements protect the gearbox components from excessive stress while allowing the engine to operate at higher power levels.
3Ease of manufacture
If traditional mounting members are used, then the gearbox is easily installed, but misalignments occur under dynamic conditions
Solution Approach 1:
The invention uses flexible mounting elements (flex mounts and flex couplings) that can deform elastically to accommodate misalignments while maintaining proper operational alignment. These flexible components are designed with specific stiffness characteristics to allow controlled movement that prevents permanent misalignment damage.
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 improved mounting assembly extends the life of gearbox components by minimizing misalignments and eccentric loading, reducing stress, and preventing premature failure, thereby enhancing durability and performance under dynamic loading conditions.
Implementation Method 1
designed to manage lateral, bending, and torsional stiffness and damping properties
Implementation Method 2
designed to manage lateral, bending, and torsional stiffness and damping properties
Data Source
AI summary
A mounting assembly for a gearbox assembly of a gas turbine engine includes at least one mounting member configured to mount a gear of the gearbox assembly to a component of the gas turbine engine, the at least one mounting member characterized by a lateral impedance parameter, a bending impedance parameter, and a torsional impedance parameter. A gas turbine engine includes the mounting assembly. The at least one mounting member may be a flex mount, a fan frame, or a flex coupling. The gas turbine engine includes an electric power system including at least one electric machine. The electric power system includes a plurality of power converters and a plurality of power distribution management units. At least two of the plurality of power converters or the plurality of power distribution management units are integrated together in a single housing.