Patent Application
20210140368
The present disclosure relates to a transmission system and more particularly, to a support mount for meshing gears in a bearing compartment of a transmission system.
A gas turbine engine typically includes a transmission system for coupling one of its spools to an accessory gearbox. Such a transmission system includes a first bevel gear (often called the bull gear) mounted to a shaft of the spool. The transmission system also includes a tower shaft and an associated second bevel gear (often referred to as the bevel gear) mounted to a first end of the tower shaft, where a second end of the tower shaft is coupled to the accessory gearbox.
With existing aircraft bull/bevel gear assemblies, the gears tend to push away from each other due to the gear tooth geometry, which can cause excessive wear on the gear teeth or even decoupling of the gears.
A bearing compartment assembly for a gas turbine engine includes an intermediate case, a towershaft, a shaft, a bull gear, a bevel gear, a towershaft bearing, and a support mount. The intermediate case includes a plurality of struts distributed circumferentially about a centerline axis. The towershaft extends through one of the struts. The shaft passes through a center of the intermediate case and extends along the centerline axis. The bull gear is connected to and extends axially from the shaft. The bevel gear is mounted to an end of the towershaft and is engaged with the bull gear. The towershaft is connected to the shaft via the bull gear and the bevel gear. The towershaft bearing surrounds and is operably connected to the towershaft. The support mount is connected to the intermediate case and extends from a surface of the intermediate case to the towershaft bearing.
A method of supporting a towershaft assembly of an engine of an aircraft against an intermediate case of the aircraft includes operating a gear assembly of the engine. The gear assembly includes a bull gear, a bevel gear, and the towershaft assembly. The bull gear is operably connected to a shaft of the engine. The bevel gear is engaged with the bull gear and is mounted on an end of a towershaft of the towershaft assembly. A towershaft bearing is attached to the towershaft such that the towershaft passes through a middle of the towershaft bearing. The towershaft bearing is supported with a mount support that includes a body plate, a first extension, and a second extension. The body plate is attached to an outer perimeter of the towershaft bearing. The first extension is connected to and extends from the body plate. A distal end of the first extension is connected to a first location of the intermediate case. The second extension is connected to and extends from the body plate. A distal end of the second extension is connected to a second location of the intermediate case. A load is transferred from the bevel gear to the towershaft, from the towershaft to the towershaft bearing, from the towershaft bearing to the support mount, from the support mount to the intermediate case, and from the intermediate case to one of a strut of the intermediate case.
The present summary is provided only by way of example, and not limitation. Other aspects of the present disclosure will be appreciated in view of the entirety of the present disclosure, including the entire text, claims, and accompanying figures.
While the above-identified figures set forth one or more embodiments of the present disclosure, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents embodiments by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the disclosure. The figures may not be drawn to scale, and applications and embodiments of the present disclosure may include features and components not specifically shown in the drawings.
Gas turbine engine 10 extends along axial centerline 12 between upstream airflow inlet 14 and downstream airflow exhaust 16. Gas turbine engine 10 includes fan section 18, compressor section 20, combustor section 22, and turbine section 24. Compressor section 20 includes LPC section 20A and HPC section 20B. Turbine section 24 includes HPT section 24A and LPT section 24B.
Fan section 18, compressor section 20, combustor section 22, and turbine section 24 are arranged sequentially along centerline 12 within engine housing 26. Engine housing 26 includes inner case 28 (e.g., a core case) and outer case 30 (e.g., a fan case). Inner case 28 may house one or more of fan section 18, compressor 20, combustor section 22, and turbine section 24 (e.g., an engine core). Outer case 30 may house at least fan section 18. Each of gas turbine engine sections 18, 20A, 20B, 24A and 24B includes respective rotors 32-40. Each of these rotors 32-40 includes a plurality of rotor blades arranged circumferentially around and connected to one or more respective rotor disks. The rotor blades, for example, may be formed integral with or mechanically fastened, welded, brazed, adhered and/or otherwise attached to the respective rotor disk(s).
Fan rotor 32 is connected to gear train 42, for example through fan shaft 44. Gear train 42 and LPC rotor 34 are connected to and driven by LPT rotor 40 through low speed shaft 46. The combination of at least LPC rotor 34, LPT rotor 40, and low speed shaft 46 may be referred to as “a low speed spool.” HPC rotor 36 is connected to and driven by HPT rotor 38 through high speed shaft 48. The combination of at least HPC rotor 36, HPT rotor 38, and high speed shaft 48 may be referred to as “a high speed spool.” Shafts 44-48 are rotatably supported by a plurality of bearings 52, which can be rolling element bearings, thrust bearings, or other types of bearings. Each of these bearings 52 is connected to engine housing 26 by at least one stationary structure such as, for example, an annular support strut.
During operation, air enters gas turbine engine 10 through airflow inlet 14. Air is directed through fan section 18 and is then split into either core gas path 54 or bypass gas path 56. Core gas path 54 flows sequentially through fan section 18, compressor section 20, combustor section 22, and turbine section 24. The air within core gas path 54 may be referred to as “core air.” Bypass gas path 56 flows through a duct between inner case 28 and outer case 30. The air within bypass gas path 56 may be referred to as “bypass air.”
The core air is compressed by LPC rotor 34 and HPC rotor 36 and directed into combustion chamber 58 of combustor 60 in combustor section 22. Fuel is injected into combustion chamber 58 and mixed with the core air that has been compressed by compressor section 20 to provide a fuel-air mixture. This fuel-air mixture is ignited and combustion products thereof expand and flow through and sequentially cause HPT rotor 38 and LPT rotor 40 to rotate. The rotations of HPT rotor 38 and LPT rotor 40 drive rotation of LPC rotor 34 and HPC rotor 36, respectively and compression of the air received from core gas path 54. The rotation of LPT rotor 40 also drives rotation of fan rotor 32, which propels bypass air through and out of bypass gas path 56. The propulsion of the bypass air may account for a majority of thrust generated by gas turbine engine 10, which can be more than 75% of engine thrust. Gas turbine engine 10 of the present disclosure, however, is not limited to the foregoing exemplary thrust ratio.
Gas turbine engine 10 of
Transmission system 66 is configured to mechanically couple and thereby transfer rotational energy (e.g., torque) between a rotating assembly (or component) of gas turbine engine 10 and accessory gearbox 62. In particular, transmission system 66 of
In existing gas turbine engines, it is common to extract power from a main shaft though a bull gear (mounted on the main shaft) into a bevel gear (mounted on the towershaft) and into the accessory gearbox. The bevel gear/towershaft can be mounted on a bearing in one of the bearing compartments that is supported by a towershaft support or a crossover housing that connects between a #2 bearing support and a #3 bearing support.
As power is extracted, the gears tend to push away from each other, due to the gear tooth geometry. To prevent excessive wear on the gear teeth or decoupling of the gears, the bevel gear and its bearing are held rigidly (against deflection) in place by its support. As power extraction through the towershaft increases, the force pushing the gears away from one another also increases. According to such designs, the towershaft support or crossover housing reacts against these deflections. As the magnitude of power extraction is increased, gear loads are consequently increased.
In some existing bearing compartment designs, utilizing a crossover housing can be impractical due to order of assembly challenges, the potential for oil leak paths, or the weight of the crossover housing itself. A towershaft support can to be more flexible than a crossover housing, increasing the potential for wear on gear teeth or for decoupling of the gears.
Bull gear 72 and bevel gear 74 are meshed gears. Intermediate case 76 is a wall element of bearing compartment 50B and is made of solid material (e.g., metal). In this example, intermediate case 76 includes a plurality of co-axial frusto-conical sheet portions. Struts 78 are hollow support structures. Support mount 80 is a support structure and includes first and second extensions 82 and 88. In one non-limiting embodiment, support mount 80 can be manufactured by machining or created by additive manufacturing. A material of support mount 80 can include steel, titanium, or nickel. First extension 82 and second extension 88 are extensions of solid material. First leg 84, second leg 86, and third leg 90 are elongate portions of support mount 80. Although not shown in
In this example, towershaft 68 passes through one of struts 78 and through support mount 80. In this non-limiting embodiment, bull gear 72 can be attached or mounted to low speed shaft 46 or to high speed shaft 48. Bevel gear 74 is attached to an end of towershaft 68. Bevel gear 74 is meshed with bull gear 72 such that the gear teeth of each are meshed with each other. Intermediate case 76 is mounted inside of bearing compartment 50B. Struts 78 extend between and connect to the frusto-conical portions of intermediate case 76.
Support mount 80 is disposed between intermediate case 76 and bevel gear 74. First leg 84 and second leg 86 of first extension 82 are connected to intermediate case 76 at a first location on intermediate case 76. First leg 84 and second leg 86 of first extension 82 are connected to intermediate case 76 with a fastener. In one example, intermediate case 76 can include fastening features such as bosses for receiving a fastener at each point where first leg 84, second leg 86, third leg 90, and the fourth leg come into contact with intermediate case 76. Third leg 90 and the fourth leg of second extension 88 are connected to intermediate case 76 at a second location on intermediate case 76. In this example, the first location of intermediate case 76 is located radially outward from the second location relative to axial centerline 12. Also in this example, the first location of intermediate case 76 is disposed further away from bull gear 72 than the second location of intermediate case 76.
In this non-limiting embodiment, distal ends of each of first and second legs 84 and 86 are shown as disposed approximately at a midpoint location (in a circumferential direction) between adjacent struts 78. In another non-limiting embodiment, the distal ends of first leg 84, second leg 86, third leg 90, and the fourth leg can be circumferentially (or radially) aligned with a strut 78 or struts 78.
Bull gear 72 and bevel gear 74 rotate and drive each other so as to transfer torque between towershaft 68 and high speed shaft 48. During operation of gas turbine engine 10, for example during high load events, bull gear 72 and bevel gear 74 can push apart from each other causing a load (e.g., force) to be placed on bevel gear 74. This load is transferred from bevel gear 74 to towershaft 68. Struts 78 provide structural support between the frusto-conical pieces of intermediate case 76. Struts 78 also transfer the load from intermediate case 76 out to an airframe of gas turbine engine 10. Support mount 80 provides structural support to towershaft 68 (e.g., via a bearing, see e.g.,
With intermediate case 76 being a structural element of gas turbine engine 10, struts 78 provide a good load path for transferring loads out of bearing compartment 50B to the airframe of gas turbine engine 10. By mounting the bearing of towershaft 68 (see e.g.,
Support mount 80 provides a weight reduction over existing types of supports used to absorb load from geared system 70. Support mount 80 improves the assembly process over existing configurations by requiring less assembly steps and because support mount 80 has tight/snap fits to adjacent components through which to pass the loads. Support mount 80 enables increased power extraction capability within existing envelopes. Support mount 80 eliminates flange separation concerns at a flange between support mount 80 and the adjacent hardware. Support mount 80 also provides the benefit of replacing an existing support feature that includes investment cast titanium and receives hot isostatic pressing, thereby simplifying the production and assembly process of gas turbine engine 10.
Fourth leg 92 is a support leg similar to third leg 90. Body plate 94 is a planar piece of solid material with an opening in its middle. Towershaft bearing 96 is a bearing such as a ball bearing or a roller bearing. Centering spring 98 is an annular support element. Fasteners 100 are mechanical fasteners such as bolts. Fourth leg 92 is connected to and extends away from body plate 94. In one non-limiting embodiment, first, second, third, and fourth legs 84, 86, 90, and 92 intersect with a surface of intermediate case 76 such that first, second, third, and fourth legs 84, 86, 90, and 92 are normal (e.g., are perpendicular, orthogonal) to the surface of intermediate case 76. In one non-limiting embodiment, body plate 94 is perpendicular to a central axis of towershaft 68.
Towershaft bearing 96 is set into and mounted to the opening of body plate 94. The inner diameter of towershaft bearing 96 is engaged with an outer surface of towershaft 68. Centering spring 98 is mounted within bearing compartment 50B (shown in
Along with first leg 84, second leg 86, and third leg 90, fourth leg 92 attaches to intermediate case 76 so as to brace support mount 80 against intermediate case 76. Fourth leg 92 helps to form the load path from towershaft bearing 96 through to intermediate case 76 and out of bearing compartment 50B through struts 78. Body plate 94 braces towershaft bearing 96 such that body plate 94 receives load from towershaft bearing 96 and transfers that load to first, second, third, and fourth legs 84, 86, 90, and 92. First, second, third, and fourth legs 84, 86, 90, and 92 in turn transfer the load from body plate 94 to intermediate case 76. Towershaft bearing 96 enables towershaft 68 to rotate relative body plate 94 of support mount 80. Fasteners 100 engage with intermediate case 76 so as to attach distal ends of first, second, third, and fourth legs 84, 86, 90, and 92 to a surface of intermediate case 76.
Support mount 180 is a support structure with six legs. Fifth leg 196 and sixth leg 198 are elongate pieces of solid material. Fifth leg 196 and sixth leg 198 are connected to and extend from body plate 194. Distal ends of fifth leg 196 and sixth leg 198 are fastened to intermediate case 76 (shown in
Fifth leg 196 and sixth leg 198 provide additional paths for the load from towershaft 68 to be transferred from support mount 180 to intermediate case 76. In this example, the combination of first leg 184, second leg 186, fifth leg 196, and sixth leg 198 create a truss pattern/structure through which the load is more evenly distributed. In other examples, cross-beams (e.g., curved or straight) may extend between and connect the distal ends of first leg 184, second leg 186, fifth leg 196, and sixth leg 198 (and/or third leg 190 and the fourth leg). Support mount 180 with fifth and sixth legs 196 and 198 further distributes the force load from towershaft 68, through support mount 180, and into intermediate case 76 so as to provide additional strength to support mount 180.
With first extension 282 and second extension 288 including a flat sheet of material, first extension 282 and second extension 288 can further distribute the load from towershaft 68 (shown in
A bearing compartment assembly for a gas turbine engine includes an intermediate case, a towershaft, a shaft, a bull gear, a bevel gear, a towershaft bearing, and a support mount. The intermediate case includes a plurality of struts distributed circumferentially about a centerline axis. The towershaft extends through one of the struts. The shaft passes through a center of the intermediate case and extends along the centerline axis. The bull gear is connected to and extends axially from the shaft. The bevel gear is mounted to an end of the towershaft and is engaged with the bull gear. The towershaft is connected to the shaft via the bull gear and the bevel gear. The towershaft bearing surrounds and is operably connected to the towershaft. The support mount is connected to the intermediate case and extends from a surface of the intermediate case to the towershaft bearing.
The assembly of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components.
The support mount can comprise a body plate attached to an outer perimeter of the towershaft bearing; a first extension connected to and extending from the body plate, wherein a distal end of the first extension can be connected to a first location of the intermediate case; and/or a second extension connected to and extending from the body plate, wherein a distal end of the second extension can be connected to a second location of the intermediate case.
The first location of the intermediate case can be located radially outward from the second location relative to the axial centerline.
The first location of the intermediate case can be disposed further away from the bull gear than the second location of the intermediate case.
The first extension can comprise first and second legs that can be fastened to the intermediate case, and/or wherein the second extension can comprise third and fourth legs that can be fastened to the intermediate case.
At least one of the first, second, third, and fourth legs can be circumferentially aligned with a strut of the plurality of struts.
The first extension can comprise a first flat sheet of material with a first curved edge that can conform to a first portion of a surface of the intermediate case.
The second extension can comprise a second flat sheet of material with a second curved edge that can conform to a second portion of the surface of the intermediate case.
At least one of the first extension and/or the second extension can comprise a truss pattern.
The compressor section can include a low pressure compressor and/or a high pressure compressor, further wherein the intermediate case can be disposed between the low pressure compressor and the high pressure compressor.
A method of supporting a towershaft assembly of an engine of an aircraft against an intermediate case of the aircraft includes operating a gear assembly of the engine. The gear assembly includes a bull gear, a bevel gear, and the towershaft assembly. The bull gear is operably connected to a shaft of the engine. The bevel gear is engaged with the bull gear and is mounted on an end of a towershaft of the towershaft assembly. A towershaft bearing is attached to the towershaft such that the towershaft passes through a middle of the towershaft bearing. The towershaft bearing is supported with a mount support that includes a body plate, a first extension, and a second extension. The body plate is attached to an outer perimeter of the towershaft bearing. The first extension is connected to and extends from the body plate. A distal end of the first extension is connected to a first location of the intermediate case. The second extension is connected to and extends from the body plate. A distal end of the second extension is connected to a second location of the intermediate case. A load is transferred from the bevel gear to the towershaft, from the towershaft to the towershaft bearing, from the towershaft bearing to the support mount, from the support mount to the intermediate case, and from the intermediate case to one of a strut of the intermediate case.
The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following steps, features, configurations and/or additional components.
The load can be transferred from the towershaft bearing to the body plate and/or from the body plate to at least one of the first and second extensions.
The support mount can be loaded compressively against the intermediate case as the load is transferred from the towershaft to the support mount.
The towershaft can be braced with the support mount against bending in an axial direction or in a tangential direction relative to an axial centerline of the engine.
While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
