Browse Topic: Bearings
The paper describes a method for optimal design of a helicopter tail shaft that considers rotordynamic effects from long shaft assembly. The tail shaft transmits power from the main gearbox (MGB) to the tail rotor of the helicopter and operates at high speeds that may exceed 6000 rpm. While higher speeds allow for weight reduction, they also pose risks associated with supercritical operation, necessitating careful design optimization. The objective of the optimization is to maximize the first three transverse natural frequencies with the constraint of the safety parameter (avoidance of the resonance/critical zone) while minimizing the weight of the system. A Non-Dominated Sorting Genetic Algorithm (NSGA-II) is used to obtain the solution to this multiobjective optimization problem, which involves shaft design variables such as length, outer diameter, and wall thickness. In addition, the optimization framework also incorporates system related design variables, including the stiffness of tail shaft bearing supports, the location of bearings, and coupling characteristics, to comprehensively evaluate and enhance the system performance. A rotordynamics model utilizing Timoshenko beam finite elements is deployed to predict natural frequencies.
The Main Gearbox of a helicopter is a crucial component that delivers the desired performance and ensures the highest possible level of safety of the aircraft; it includes several gears and bearings, which require to be continuously lubricated by a pressurized oil flow. Undesired circumstances may cause the oil to leak from the main circuit, hence reducing its pressure and consequently the oil flow rate targeted towards the rotating components; this modifies their friction coefficient, and subsequently leads to an overheating of the parts with the risk of degenerating in a catastrophic failure. During the design of a helicopter drive system, engineers need to take proper precautions and make sure that the MGB is fully equipped with the proper features to cope with a loss of lubrication event; specifically, the drive system is supposed to be able to run at least 30 minutes after the oil pressure drops to zero. A lot of effort has been put over the years at Leonardo Helicopters to find robust solutions to attain the longest performance of the drive system in no-oil conditions: the most important result is the certification of the AW189 for a 50-minutes “run dry” capability. Nevertheless, the dynamic environment typical of the rotorcraft industry pushes towards continuous innovation, and in the last few years the Transmissions Systems Design department of LH has been asked to investigate suitable ways to further augment the no-oil capabilities of the MGB: the main steps followed and entailed results are presented in this paper. The first part of the manuscript discusses the “state of the art” auxiliary lubrication system, currently flying on the AW189 drive system. The second part tackles the approach adopted to meet the novel requirements, unveiling both the methodology and the final design choice: the latter includes a metering element, able to tune the oil flow rate headed towards the component deemed the most critical in order to satisfy the requirement of longer no-oil performance. Numerical and experimental tools are exploited as complementary tools to properly crystallize the obtained results and corroborate the solution.
A typical helicopter drive system consists of a multi-stage gearbox with highly loaded dynamic components such as gears, shafts, and bearings, crucial for safe flight and landing. Planetary reduction stages are commonly used in the final reduction stage of rotorcraft main gearboxes due to their ability to handle high torques at high gear ratios within a compact envelope. The planet gear, a critical component in this arrangement, is subjected to significant loads on both flanks of its teeth and must meet stringent weight and assembly requirements, leading to a thin rim design with integrated bearing races. This design makes the planet gear susceptible to relevant reduction of its fatigue life. This paper explores analysis methods to evaluate the damage resistance of the planetary stage assembly, focusing on the planet gear. The study aims to assess the "growth" or "no growth" condition of the planet gear against defined flaw defects. An iterative calculation loop determines the critical length and position of a crack that may lead to full crack propagation and, in worst cases, to system jamming. Initial crack propagation simulations use NASGRO software, with stress fields derived from a non-linear FEM of the planet gear availing of detailed Transmission3D model for teeth meshing forces evaluation. Further additional analysis can involve a dedicated FE model of the crack, iteratively updating its geometry. The impact of crack propagation on the remaining components of the planetary stage assembly is also addressed, considering the unbalanced load conditions caused by stiffness loss in the planet gear. The dissertation object of this paper aims to outline a comprehensive, effective and efficient procedure to determine the maximum allowable defect size for "no growth" condition and the operational hours until failure, providing a robust approach to support the strength substantiation of the involved components.
Bench-level tribological experiments were utilized to evaluate material, coating, and lubricant formulation effects on the loss-of-lubricant survivability of tapered roller end and cone rib contacts. Cone rib and roller end contacts were simulated using a single rotating roller and rotating flat disk. The applied load and rotational speeds of the roller and disk were controlled to simulate representative rotorcraft gearbox bearing operating conditions. The contacts were lubricated for an initial period before the lubricant supply was shut off, and the supply tube was then removed. Tests continued to run, without additional oil, until the measured friction force reached a predetermined cutoff value. Weibull-based statistical analysis was used to compare the loss-of-lubrication runtimes.
This paper presents experimental research aimed at developing novel low lubrication methods for rotorcraft and jet engines, focusing on sustaining minimal lubrication to prevent catastrophic bearing failure during loss of lubrication (LoL) events or to increase fuel consumption performance on once-through, fuel-oil bearing lubrication engines. Utilizing two high-speed bearing test rigs simulating low and high thrust class engine conditions, the study establishes lower bounds for oil flow rates necessary to maintain thermal stability and prevent thermal runaway in hybrid ball bearings. These findings inform the design of the Zulu Pod (ZPod), a passively driven, self-contained oil delivery system that uses engine compressor bleed air to precisely meter lubricant flow. Engine test stand results demonstrate that replacing traditional fuel-oil lubrication with the ZPod system reduces thrust specific fuel consumption (TSFC) by an average of 7%, with up to 11% savings, without compromising engine thrust or bearing health. The ZPod offers a simplified, efficient alternative to fuel-lubricated systems by eliminating fuel diversion for lubrication, enhancing fuel efficiency, and maintaining bearing performance in attritable or single-use engines. Additionally, the study highlights the potential of minimal lubrication supplied by the ZPod to extend operational life during LoL scenarios, enabling safer aircraft recovery. Future work will focus on extending testing to higher thrust classes and optimizing ZPod designs for broader applications.
Wear debris monitoring and analysis is a common practice for the condition assessment of engine and transmission health. Oil debris monitoring (ODM) and electronic chip detectors (ECD) are two common methods deployed for continuous monitoring of oil wetted component health in-flight. This study evaluates the diagnostic performance of the two sensing technologies within controlled rolling element bearing (REB) fault experiments. Progressive visual inspection of the REB spall progression through failure provided a ground truth against which both systems could be compared. Quantifiable metrics of reliability, diagnostic accuracy, provided maintenance interval were defined to create a framework for condition-based maintenance (CBM) program decision making. In summary, it was found that the ODM sensor system provided earlier fault notice, but more so, vastly outperformed the ECD in reliability and avoidance of false positives.
The succession of the BK117 D-2 main rotor concept from the semi-rigid rotor to the BK117 D-3 bearingless main rotor (BMR) system, derived from the H135, held many new and innovative additional benefits in its wake. Although the H135 system is the best on the market regarding maintenance effort and maintenace cost (DMC), it was the purpose to push this benchmark even further. To achive additional benefits, three major improvements needed to be successfully implemented and none of them was a given. First to mention is the concept of the blade being separated in three parts. In case of foreign object damage (FOD), most of the time only the outer part needs to be repaired. In parallel a new possibility to fold the system with a full folding capacity was introduced with the challenge to realize the extremely low DMCs of the H135, in a decisively bigger helicopter and to benefit from the experience of millions of flight hours and thousands of helicopters operated throughout the world. Second a reduced flapping hinge offset was introduced to improve the comport of ride. The third point is the attachment bearing stress laminate providing the benefit of slim shape in the connection area between Flex control unit (FCU) and blade airfoil section. All this with the reduction of vibration in mind that results from changing a four-bladed rotor to a five-bladed one [1]. We were motivated to include also a, for such kind of critical part, new liquid infusion molding technology, to have all process parameters in our own hands, to make the production of blades more reliable and at the same time reduce the number of nonconformities by introducing more and more automation in production, which was enabled using the bearing laminate design of the attachment [2]. This innovative new design, in combination with a new manufacturing process introduced in a different production site under considerable time and cost pressure, needed the dedication of a multi-disciplinary transnational team, to finally overcome all deviations that became visible throughout the industrialization and/or prototype phase. This finally led to a mature serial production within a two years time frame. The paper is intended to highlight the often shortened and only briefly recognized period of preproduction, prototyping and the serialization and maturation of critical composite parts.
Rolling element bearing failures form one of rotating equipment's most critical failure modes. Vibration analysis has been successfully used for bearing fault detection and diagnostics but does not estimate the spall length of the bearing. An estimate of the spall length would provide insight into the degrading reliability of a drivetrain as the fault propagates. This would improve the timeliness of scheduling a maintenance action. In this paper, a synthetic tachometer signal is generated from the bearing fault itself. It is synchronous to the rolling element, allowing for a time-domain representation of waveform using the time-synchronous average. From this, an estimate of the length of the bearing fault can be determined.
Over 4 decades of research works on the nutating, now pericyclic, mechanical transmission have studied its capability to achieve high power density, low noise, and amplified single-stage reduction ratios of up to 100:1. These analytical efforts have culminated into the fabrication of a 50 HP and 32:1 reduction ratio pericyclic transmission prototype. This work introduces the prototype with highlights of the assembly and alignment procedures validated by static testing evaluation. Then, discussion of the dynamic test stand integration, instrumentation, and lubrication components lay out the framework of the high-speed testing plan. Power transmission data validated the pericyclic reduction ratio model. Accelerometer data demonstrated the transmission's capability to operate at low vibration, with peak amplitudes of 1.2 and 2.5 inches per second on the pericyclic gear train and output shaft respectively. Acoustic emission data captured the first 5 harmonics of the shaft speed as well as gear mesh frequencies. The thermal profile showed the shaft bearings remained below 180°F throughout testing, implying safe operating conditions. Finally, strain and vibration data showed the pericyclic gear train maintained load sharing throughout the entire operating envelope, further validating static testing and assembly procedures. The results of the experiments demonstrate the technological readiness of pericyclic mechanical transmission.
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In the winter months of January-March 2019, two Bell 525 test aircraft completed cold weather testing at Yellowknife Canada, some 1900 nm from Bell’s Flight Research Center in Arlington, TX. Testing was aimed at demonstrating aircraft stability, performance, and flight characteristics at extreme temperatures as required by CFR Part 29. Since regulations only permit limited temperature extrapolation, the cold temperature tests must include the limit of forward speed in a dive (VNE), and assessments of performance, controllability, autorotation, and static stability. This paper describes some of the unique environmental conditions and factors that any rotorcraft development program could experience in cold weather testing. The paper also gives a technical description of the required testing, where arctic conditions reached as low as -40° F or C (the temperature scales are the same at this temperature). Testing exposed the aircraft to overnight cold-soaks that brought fluids, seals, windshields, electronics, and elastomeric bearings to their low temperature specification, all at the same time. For the 525, test results demonstrated that the aircraft was ready for start-up and operation in extreme cold. The criteria necessary for meeting certification requirements in cold weather were also demonstrated in the series of tests and showed that the rotor was free from any adverse effects due to aerodynamic compressibility, had low vibration, acceptable loads and was free from any instability, even at speeds greater than VNE.
The subject of the research in this paper is to achieve longer and more reliable loss of lubrication (LoL) performance. The research developed the computational thermal analysis model including airflow inside and outside transmissions to predict thermal behavior under LoL. And the research conducted the LoL performance test using the modified BK117D2 (EC145T2) main transmission optimally designed with the computational analysis. Data measurement during the test included temperatures of rotating components such as gears and bearings, temperature distribution on the gear teeth, and airflow speeds and heat fluxes around the transmission in order to analysis the test result. The test procedure was according to the EASA new rule, which has severer test condition than the past rule. The test result shows longer LoL performance than the past test of the BK117D2 main transmission. And the computational analysis model was validated with the measured data. Then, the failure cause and possible future improvements were investigated based on the measured data and the analysis model. Finally the research concluded the modifications on the transmission, the computational analysis model and the measured data are able to make LoL performance longer and more reliable.
On August 1, 1963, the first two Canadian Sea King helicopters arrived at their new home station, Shearwater, Nova Scotia and joined the Royal Canadian Navy. On Saturday, December 1, 2018, three Canadian Sea King helicopters, now part of the Royal Canadian Air Force, made their final flight over their home station at Patricia Bay, British Columbia. This paper outlines some of the highlights of the intervening 55 years with particular emphasis on procurement and fleet introduction, the helicopter's rapid change of roles from dedicated anti-submarine warfare helicopter to a general-purpose surveillance platform for the First Gulf War and finally, the truly amazing accomplishments of the Canadian Sea Kings in the year 2010. It is worth bearing in mind that although the personnel may have changed and the roles and equipment of the aircraft have been modified, the requirement to provide ‘Wings for the Fleet’ has remained constant over the years.
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