Gearbox Mounting Assembly With Tuned Stiffness for Misalignment Control
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Solution Overview
Problem
The existing mounting assemblies for gearbox assemblies in gas turbine engines face challenges in accommodating increasing thrust and power, leading to misalignments and premature failure of gearbox components due to dynamic loading and relative movements.
Innovation Solution
The proposed solution involves a mounting assembly with specific impedance parameters for the flex coupling, flex mount, and fan frame, which are optimized to provide lower lateral and bending stiffness ratios while maintaining higher torsional stiffness ratios compared to the fan frame, thereby reducing edge loading and stress on gearbox components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the mounting assembly uses higher lateral and bending stiffness to support increasing thrust and power, then the load-bearing capacity is improved, but misalignments and edge loading increase leading to premature gearbox component failure
Solution Approach 1:
The patent applies parameter changes by optimizing the stiffness characteristics of mounting components. Specifically, it adjusts the lateral and bending stiffness ratios of the flex coupling and flex mount relative to the fan frame, creating a compliant mounting assembly that distributes loads more uniformly and prevents misalignments while maintaining adequate load-bearing capacity for increasing thrust and power requirements
Solution Approach 2:
The patent employs composite structural design in the mounting assembly, combining multiple components (flex coupling, flex mount, fan frame) with different stiffness properties. This composite approach allows the assembly to achieve both high load-bearing capacity and compliance, as each component contributes its specific mechanical properties to the overall system performance
2Reliability
If the mounting assembly uses lower lateral and bending stiffness ratios, then misalignments and edge loading are reduced, but the ability to support increasing thrust and power is compromised
Solution Approach 1:
The patent resolves this contradiction through parameter optimization by establishing specific stiffness ratio relationships. The flex coupling and flex mount are designed with controlled lateral and bending stiffness ratios relative to the fan frame, creating a compliant yet capable mounting system that simultaneously achieves reduced misalignments and adequate thrust/power support
Solution Approach 2:
The patent introduces dynamic compliance into the mounting assembly through the flex coupling and flex mount components. These elements allow controlled elastic deformation under load, enabling the assembly to adapt to operational conditions while maintaining proper alignment and distributing stresses, thus supporting increasing thrust and power without rigid constraint
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 optimized mounting assembly design enhances the alignment and durability of gearbox components by distributing torque loads more uniformly, reducing the risk of misalignment and premature failure, and extending the lifespan of gearbox parts.
Implementation Method 1
The proposed solution involves a mounting assembly with specific impedance parameters for the flex coupling, flex mount, and fan frame, which are optimized to provide lower lateral and bending stiffness ratios while maintaining higher torsional stiffness ratios
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.