Hydrodynamic Thrust Bearing Foil Assembly

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Solution Overview

Problem

Hydrodynamic thrust bearings face challenges with weight reduction and distortion resistance due to manufacturing processes, which can lead to decreased service life and complex assembly, particularly with the EDM process causing burrs and distortions.

Innovation Solution

A hydrodynamic thrust bearing design featuring an annular plate with arcuate bearing foils attached to one face and corrugated bumper foils attached to the opposite face, using spacers to support the foils and promote fluid film formation, and employing a chemical etching process to avoid burrs, with resistive welding to minimize heat-induced distortions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding process is used to attach bearing foils and bumper foils to the annular plate, then the foils can be securely joined, but heat-induced distortions occur in the annular plate that inhibit fluid film formation and decrease bearing performance

Engineering Contradiction:

Improvejoint strengthVSAvoidannular plate geometry

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent introduces spacers as intermediary elements between the annular plate and the bearing/bumper foils. These spacers are attached to the annular plate and provide a mounting surface for the foils, thereby mediating the connection and preventing direct heat transfer to the annular plate during welding, thus avoiding thermal distortion while maintaining secure joints

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If multiple annular plates are used to prevent distortion, then welding distortions are reduced, but the bearing weight increases and assembly complexity increases

Engineering Contradiction:

Improvedistortion resistanceVSAvoidbearing weight

Core Design Contradiction:

Manufacturing precisionVSWeight of moving object

Solution Approach 1:

The patent extracts the anti-distortion function from the annular plate structure itself and implements it through separate spacers that are attached to the annular plate. This allows the annular plate to remain a single, lightweight component while the spacers provide the necessary geometric stability and distortion resistance, avoiding the need for multiple heavy annular plates

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If EDM process is used to manufacture bearing components, then precise shaping is achieved, but burrs and metallic crust are formed on machined edges that lead to cracks and reduced service life

Engineering Contradiction:

Improvecomponent geometryVSAvoidservice life

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent converts the harmful effect of EDM burrs by implementing a finishing process that specifically removes these burrs and metallic crust from machined edges. This transforms the harmful residual defects into an opportunity for enhanced surface quality and crack prevention, thereby converting a manufacturing disadvantage into a reliability advantage

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 design achieves a lightweight, distortion-resistant thrust bearing with improved service life by preventing burrs and maintaining the intended geometry, enhancing fluid film formation and reducing assembly complexity.

Implementation Method 1

employing a chemical etching process to avoid burrs

Methodology Applied

Scientific EffectChemical etching:

Implementation Method 2

employing a chemical etching process to avoid burrs, with resistive welding to minimize heat-induced distortions

Methodology Applied

Scientific EffectResistive welding:

Implementation Method 3

Hydrodynamic thrust bearings rely on relative rotation between a shaft, typically referred to as the thrust runner, and a bearing to generate a non-linear fluid film between the thrust runner and the bearing

Methodology Applied

Scientific EffectHydrodynamic fluid film formation:

Data Source

PatentUS9470260B2Thrust bearing assembly

Publication Date: 2016.10.18 HAMILTON SUNDSTRAND CORP

AI summary

A hydrodynamic thrust bearing has an annular plate, a plurality of bearing foils, and a plurality of bumper foils. The annular plate has a first face and a second face opposite the first face. The bearing foils have an arcuate shape and are joined to the first face of the annular plate. The bumper foils have an arcuate and corrugated shape and are joined to the second face of the annular plate. A method of making a hydrodynamic thrust bearing includes joining the bearing and bumper foils to the annular plate with integrally-formed spacers in which each bumper foil corresponds to a bearing foil.