Planet Carrier Box Structure for Lightweight Gearbox Strength
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Solution Overview
Problem
The challenge is to manufacture gearbox components for gas turbine engines that are both lightweight and possess the necessary structural integrity to withstand operational forces, while minimizing mass and avoiding the use of expensive, complex equipment.
Innovation Solution
A method involving the manufacturing of preforms through additive layer manufacturing, which are then folded and secured to form a box support structure, using interlocking features and fasteners, and integrated with metal rings to create a planet carrier that optimizes material density and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If single-piece high-strength steel forging is used to construct gearbox components, then structural integrity and strength are improved, but device complexity and manufacturing cost increase due to large, complex and expensive equipment requirements
Solution Approach 1:
The invention divides the planet carrier into multiple separate components: a support structure made from additive-manufactured preforms and metal rings, and planet gears. This segmentation allows each component to be manufactured independently using simpler, more cost-effective processes while maintaining overall structural integrity through designed connection interfaces.
Solution Approach 2:
The invention changes the manufacturing approach from traditional subtractive machining of solid steel blocks to additive layer manufacturing of preforms followed by folding and assembly. This parameter change in the manufacturing process enables the use of lighter materials and simpler equipment while achieving the required strength through optimized geometry and material distribution.
2Strength
If single-piece high-strength steel forging is used to construct gearbox components, then structural integrity is improved, but weight increases which is undesirable for gas turbine engines
Solution Approach 1:
The invention applies local quality by varying the material distribution and density within the preforms to match the local structural requirements. The additive manufacturing process allows for optimized material placement where strength is needed, while reducing material in areas where it is not required, achieving high strength-to-weight ratio.
Solution Approach 2:
The invention uses composite construction by combining additive-manufactured preforms (which can be made from lighter materials) with metal rings and fasteners. This composite approach allows each material to be selected for its optimal properties, resulting in a lighter overall structure that meets strength requirements.
3Weight of moving object
If traditional manufacturing methods are used to minimize component mass, then weight is reduced, but structural integrity may be compromised under enormous operational forces
Solution Approach 1:
The invention performs preliminary action by manufacturing preforms with built-in features such as folded sections, hollow chambers, and integrated fastening elements before final assembly. These pre-formed structures are designed to provide the necessary strength and structural integrity while minimizing weight, eliminating the need for heavy reinforcement during final assembly.
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 approach enables the production of lightweight, high-strength gearbox components that effectively withstand operational forces, reducing material costs and complexity in the manufacturing process.
Implementation Method 1
manufacturing the preforms by additive layer manufacturing to from a plurality of preforms comprising fused/sintered powdered material
Implementation Method 2
preforms comprising fused/sintered powdered material
Data Source
AI summary
A method of manufacturing a planet carrier of a gearbox comprises manufacturing a plurality of preforms. Each preform comprises a base portion, a first end portion connected to a first end of the base portion, a second end portion connected to a second end of the base portion, a first side portion connected to a first side of the base portion, a second side portion connected to a second side of the base portion and a top portion. The first and second end portions and the first and second side portions are folded relative to the base portion and the top portion is folded and the adjacent edges of the portions of each preform are secured together to form a support structure. A first ring and a second ring are manufactured. The first and second end portions of each support structure are secured to the first and second rings respectively.