Weld-Free Thrust Bearing Assembly for Uniform Wear
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Solution Overview
Problem
Hydrodynamic thrust bearings face issues with structural distortion and uneven wear due to the labor-intensive and costly welding process, which affects fluid film formation and bearing performance.
Innovation Solution
A thrust bearing arrangement is designed without welding, featuring a top plate, thrust plate, and bump plate with no welds, where the components are photochemically etched and pressed to form monolithic structures with solid film lubricant coatings, ensuring uniform wear and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to assemble thrust bearing components, then the components can be joined together to form a complete bearing structure, but the welding process causes structural distortion of the annular support plate due to uneven heating
Solution Approach 1:
The thrust bearing is divided into separate modular components (annular support plate, top foils, bump foils) that are assembled without welding. Each component maintains its structural integrity independently, eliminating welding-induced distortion while allowing for precise shaping of each segment.
Solution Approach 2:
A non-welding connection method is introduced as an intermediary between the annular support plate and the foil components. This intermediary assembly process avoids direct thermal contact and welding, thereby preventing structural distortion while still achieving functional joining.
2Strength
If welding is used to assemble thrust bearing components, then the components can be joined together, but the welding process is labor intensive and increases production cost
Solution Approach 1:
The bearing is segmented into pre-fabricated components that can be manufactured independently using standardized processes. This segmentation eliminates the need for complex welding operations during assembly, reducing labor intensity and manufacturing complexity while maintaining joint strength through precise mechanical fitting.
Solution Approach 2:
The manufacturing approach transitions from thermal joining (welding) to a cold-assembly process. By changing the joining parameter from high-temperature welding to precision mechanical assembly, the labor intensity and manufacturing complexity are significantly reduced while maintaining component strength.
3Strength
If welding is used to assemble thrust bearing components, then the components can be joined together, but the welding process distorts the annular support plate which alters fluid film formation and decreases bearing performance
Solution Approach 1:
The bearing structure is segmented into separate components that are assembled without welding, preventing distortion of the annular support plate. This maintains the precise geometry required for proper fluid film formation between the thrust runner and bearing surfaces, thereby preserving bearing performance and reliability.
Solution Approach 2:
A non-welding assembly process serves as an intermediary that joins components without causing thermal distortion. This intermediary process preserves the critical surface geometries and fluid film formation characteristics necessary for reliable bearing operation.
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 provides thrust bearings with reduced structural distortion, long service life, uniform wear, and lower production costs compared to traditional welding methods, enhancing performance and efficiency.
Implementation Method 1
The top plate, the thrust plate, and the bump plate may be photochemically etched from respective metal sheets
Implementation Method 2
relative rotation of the shaft and the bearing interacts with fluid to create and maintain pressurized wedges of fluid between the shaft and the bearing. The pressurized fluid wedge, in turn, transfers thrust or axial loads from the thrust runner to the bearing
Implementation Method 3
A thrust bearing arrangement includes a top plate extending about a rotation axis, a thrust plate extending about the rotation axis and axially offset from the top plate
Data Source
AI summary
A thrust bearing arrangement includes a top plate extending about a rotation axis, a thrust plate extending about the rotation axis and axially offset from the top foil plate, and a bump plate. The thrust plate is orthogonal relative to the rotation axis. The bump foil plate extends about the rotation axis, is axially offset from the thrust plate, and has an annular portion and two or more bump plate foil portions. The annular portion of the bump plate is circumferentially interrupted by the bump plate foil portions of the bump plate. Rotating machines and methods of making thrust bearing arrangements for rotating machines are also described.