Sealed Bearing Assembly With Inlet Headers for Oil Distribution
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Solution Overview
Problem
Conventional bearing assemblies in gas turbine engines are bulky, consume large amounts of oil and air, and require significant power for heat rejection, leading to high operating costs and fuel consumption.
Innovation Solution
A sealed bearing assembly with inlet headers and sealing members, formed from sintered materials using additive manufacturing, that localizes oil distribution and sealing within a cavity between the inner and outer races, reducing oil and air usage and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional bearing assemblies are used with open sump cavities, then the bearing assembly can be simple in structure, but the assembly becomes bulky and heavy with large oil consumption
Solution Approach 1:
The bearing assembly is segmented into a sealed bearing unit with its own dedicated cavity, separated from the main sump. This segmentation allows the bearing to be self-contained with controlled lubrication, reducing the need for large sump cavities and associated sealing systems, thereby reducing overall weight while maintaining structural simplicity
Solution Approach 2:
A flexible sealing member (such as a lip seal or oil-impregnated felt seal) is used to seal the bearing cavity. This flexible seal effectively prevents oil leakage without requiring complex rigid sealing structures, enabling a compact lightweight design while maintaining bearing functionality
2Reliability
If large quantities of oil are used for lubrication, then the bearing can be adequately lubricated, but the oil must be stored, pumped, filtered, and cooled consuming significant power
Solution Approach 1:
The bearing assembly is designed as a self-contained unit with an integrated oil reservoir and lubrication system. The bearing uses its own stored oil for lubrication without requiring external pumping, filtering, or cooling systems. This self-service approach ensures adequate lubrication while eliminating the power consumption associated with external oil management systems
Solution Approach 2:
The oil reservoir is nested within or integrated with the bearing assembly structure. The reservoir, sealing member, and bearing elements are nested together to form a compact self-contained unit. This nesting eliminates the need for separate external oil storage and management systems, reducing power consumption while ensuring reliable lubrication
3Device complexity
If open sump cavities are used with air flow for sealing, then the system can be simple, but large quantities of air are consumed and heat rejection requires power
Solution Approach 1:
A flexible sealing member (such as a lip seal or oil-impregnated felt seal) is used to seal the bearing cavity. This flexible seal effectively prevents oil leakage without requiring complex rigid sealing structures, enabling a compact lightweight design while maintaining bearing functionality
Solution Approach 2:
The bearing cavity is sealed to create a controlled environment that prevents contamination and maintains lubrication. This sealed inert environment eliminates the need for continuous air flow for sealing purposes, reducing energy loss while keeping the sealing system simple
4Reliability
If oil is sprayed directly onto the bearing, then lubrication is provided, but the oil drains into the sump creating a frothy mixture requiring large sump cavities
Solution Approach 1:
The bearing assembly is segmented into a sealed bearing unit with its own dedicated cavity, separated from the main sump. This segmentation allows the bearing to be self-contained with controlled lubrication, reducing the need for large sump cavities and associated sealing systems, thereby reducing overall weight while maintaining structural simplicity
Solution Approach 2:
A flexible sealing member (such as a lip seal or oil-impregnated felt seal) is used to seal the bearing cavity. This flexible seal effectively prevents oil leakage without requiring complex rigid sealing structures, enabling a compact lightweight design while maintaining bearing functionality
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 solution reduces oil and air consumption, decreases machine weight, and lowers specific fuel consumption and operating costs by providing efficient lubrication and cooling within the bearing assembly.
Implementation Method 1
at least one of the inner race, the outer race, and the first inlet header is formed of a sintered material
Implementation Method 2
The inlet headers are formed such that oil channeled through the oil nozzles into the cavity is highly localized
Implementation Method 3
a first sealing member extending between the first inlet header and a first surface of the inner race
Implementation Method 4
The inlet headers are formed such that oil channeled through the oil nozzles into the cavity is highly localized
Data Source
AI summary
A sealed bearing assembly includes an inner race, a bearing element, and an outer race extending radially in axial alignment between a rotatable member having an axis of rotation and a stationary support structure. The sealed bearing assembly also includes a first inlet header coupled to a first axial end of the outer race. The first inlet header includes at least one oil inlet port, at least one oil nozzle, and a first sealing member extending between the first inlet header and a first surface of the inner race.