Turbomachine Speed Reducer Flange Gear Coupling for Compact Torque Transfer
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Solution Overview
Problem
Existing mechanical speed reducers in turbomachines face challenges in efficiently transmitting torque while managing weight, assembly complexity, and integration within restricted spaces, particularly due to limited screw attachment and gooseneck interference.
Innovation Solution
A mechanical speed reducer design featuring a gear coupling with axial coupling teeth between attachment flanges, reducing the need for screws by 90% and enhancing torque transmission capacity by 50%, utilizing a curvic coupling type to simplify assembly and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the diameter of attachment flanges is increased to increase torque transmission capacity, then the torque transmission capacity is improved, but the number of screws is limited and the speed reducer diameter increases impacting integration into restricted space
Solution Approach 1:
The invention transitions from a traditional bolted flange connection (2D surface contact) to a gear coupling with axial coupling teeth (3D interlocking engagement). The coupling teeth extend axially between the flanges, creating a three-dimensional engagement that dramatically increases torque transmission capacity without requiring larger flange diameters, thus resolving the contradiction between force transmission and spatial integration.
Solution Approach 2:
The gear coupling divides the torque transmission function into multiple discrete coupling teeth (typically 6-12 teeth around the circumference). Each tooth independently transmits a portion of the torque, and the cumulative effect of all teeth provides the total torque capacity. This segmentation allows high torque transmission within a compact diameter, avoiding the need to increase overall flange size.
2Ease of operation
If traditional bolted connection is used to attach flanges, then assembly is straightforward, but the number of screws required is large increasing weight and assembly time
Solution Approach 1:
The invention merges the functions of multiple separate bolts into a single integrated gear coupling mechanism. Instead of requiring numerous individual bolts distributed around the flange interface, the gear coupling provides a unified interlocking structure that accomplishes the same torque transmission function with far fewer attachment members (typically 6-12 instead of 20+ bolts), reducing weight and simplifying assembly.
Solution Approach 2:
The gear coupling serves multiple functions simultaneously: it transmits torque, provides mechanical interlocking, and acts as a positioning feature for the flanges. This multi-functionality eliminates the need for separate positioning features and reduces the total number of attachment members required, addressing both assembly simplicity and quantity of components.
3Reliability
If ring gear carrier includes bellows to centre ring gear and connect to casing, then misalignment and displacement are limited, but manufacturing becomes complex and assembly is tedious
Solution Approach 1:
The gear coupling's axial coupling teeth inherently provide self-centering and alignment functions. As the coupling teeth engage between the flanges, they automatically position the components correctly without requiring external bellows or complex alignment mechanisms. The geometry of the coupling teeth themselves provides the alignment tolerance, eliminating the need for additional manufacturing complexity.
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 gear coupling design significantly increases torque transmission capacity, simplifies assembly, reduces weight, and enhances reliability by providing larger contact surfaces and fewer attachment members, thus improving the efficiency and durability of turbomachine components.
Implementation Method 1
the attachment assembly comprises at least one gear coupling with axial coupling teeth comprising a first series of axial coupling teeth intended to engage with a second series of complementary axial coupling teeth
Implementation Method 2
The passage of the torque is transmitted by friction between these surfaces
Implementation Method 3
the attachment members being arranged so as to clamp the first and second attachment flanges together and circumferentially hold each tooth of the first series of axial coupling teeth between two teeth of the second series of complementary axial coupling teeth
Data Source
AI summary
A speed reducer for a turbomachine for an aircraft, of longitudinal axis X, the speed reducer including an external ring gear and a ring gear carrier attached to the external ring gear which comprises a first attachment flange extending radially outwards and attached to a second attachment flange of the ring gear carrier by attachment members. The turbomachine including a gear coupling with axial coupling teeth including a first series of teeth engaging with a second series of complementary teeth, a portion of the first attachment flange including a portion of the gear coupling, the attachment members being arranged so as to clamp the first and second attachment flanges and circumferentially hold each axial tooth of the first series of teeth between two axial teeth of the second series of complementary teeth.