U.S. patent application number 16/561943 was filed with the patent office on 2021-03-11 for thrust bearings, rotating machinery having thrust bearings, and methods of making thrust bearings.
The applicant listed for this patent is Hamilton Sundstrand Corporation. Invention is credited to William R. Fiske, Murtuza Lokhandwalla, Ali Shakil.
Application Number | 20210071710 16/561943 |
Document ID | / |
Family ID | 1000005414144 |
Filed Date | 2021-03-11 |
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United States Patent
Application |
20210071710 |
Kind Code |
A1 |
Shakil; Ali ; et
al. |
March 11, 2021 |
THRUST BEARINGS, ROTATING MACHINERY HAVING THRUST BEARINGS, AND
METHODS OF MAKING THRUST BEARINGS
Abstract
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.
Inventors: |
Shakil; Ali; (West Hartford,
CT) ; Lokhandwalla; Murtuza; (South Windsor, CT)
; Fiske; William R.; (Springfield, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hamilton Sundstrand Corporation |
Charlotte |
NC |
US |
|
|
Family ID: |
1000005414144 |
Appl. No.: |
16/561943 |
Filed: |
September 5, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16C 43/00 20130101;
F16C 17/042 20130101; F16C 2223/30 20130101; F16C 2226/00
20130101 |
International
Class: |
F16C 17/04 20060101
F16C017/04; F16C 43/00 20060101 F16C043/00 |
Claims
1. A thrust bearing arrangement, comprising: a top plate extending
about a rotation axis; a thrust plate extending about the rotation
axis and axially offset from the top plate, the thrust plate
orthogonal to the rotation axis; and a bump plate extending about
the rotation axis and axially offset from the thrust plate, the
bump plate having a bump plate annular portion and a plurality of
bump plate foil portions, wherein the bump plate annular portion is
circumferentially interrupted by the plurality of bump plate foil
portions, wherein the plurality of bump plate foil portions extend
axially from the bump plate annular portion in a direction axially
opposite the top plate; the top plate has a top plate annular
portion and a plurality of top plate pad portions, wherein the top
plate annular portion is circumferentially interrupted by the
plurality of top plate pad portions, wherein a solid film lubricant
coating is conformally disposed over the top plate annular portion
and the plurality of top plate pad portions; and the thrust plate
has a radially inner periphery and a radially outer periphery with
a plurality of ramp portions defined therebetween, the radially
inner periphery and the radially outer periphery each, except at an
anti-rotation feature on the radial outer periphery, extending
continuously about the rotation axis, the plurality of ramp
portions distributed circumferentially about the thrust plate.
2. (canceled)
3. The thrust bearing arrangement of claim 1, wherein the top plate
annular portion has a radially inner periphery, the radially inner
periphery of the top plate extending continuously about the
rotation axis and at a singular radial offset from the rotation
axis.
4. The thrust bearing arrangement of claim 1, wherein the top plate
annular portion has a radially outer periphery, the radially outer
periphery of the top plate annular portion, except at an
anti-rotation feature on the radial outer periphery, extending
continuously about the rotation axis and at a singular radial
offset from the rotation axis.
5. The thrust bearing arrangement of claim 1, wherein the plurality
of top plate pad portions extend axially from the top plate annular
portion in a direction axially opposite the bump plate.
6. (canceled)
7. (canceled)
8. The thrust bearing arrangement of claim 1, wherein the bump
plate annular portion has a radially inner periphery, the radially
inner periphery of the bump plate annular portion extending
continuously about the rotation axis and at a singular radial
offset from the rotation axis.
9. The thrust bearing arrangement of claim 1, wherein the bump
plate annular portion has a radially outer periphery, the radially
outer periphery of the bump plate annular portion, except at an
anti-rotation feature on the radial outer periphery, extending
continuously about the rotation axis and at a singular radial
offset from the rotation axis.
10. (canceled)
11. The thrust bearing arrangement of claim 1, wherein the top
plate has an anti-rotation feature, wherein the thrust plate has an
anti-rotation feature, and wherein the bump plate has an
anti-rotation feature.
12. The thrust bearing arrangement of claim 1, wherein the top
plate has a top plate annular body including a top plate annular
portion interconnecting a plurality of top plate pad portions, the
top plate annular body having no welds.
13. The thrust bearing arrangement of claim 1, wherein the bump
plate has a bump plate annular body including the bump plate
annular portion and the plurality of bump plate foil portions, the
bump plate annular portion interconnecting the plurality of bump
plate foil portions, the bump plate annular body having no
welds.
14. A rotating machine, comprising: a thrust bearing arrangement as
recited in claim 1, wherein the bump plate has a bump plate annular
body including the bump plate annular portion and the plurality of
bump plate foil portions, the bump plate annular portion
interconnecting the plurality of bump plate foil portions, the bump
plate annular body having no welds, wherein the top plate has a top
plate annular portion and a plurality of top plate pad portions,
wherein the top plate annular portion is circumferentially
interrupted by the plurality of top plate pad portions; a stator
member arranged along the rotation axis and opposing the thrust
bearing arrangement; and a shaft member arranged along the rotation
axis and opposing the thrust bearing arrangement, the shaft member
and the stator member defining therebetween a bearing chamber,
wherein the thrust bearing arrangement is disposed within the
bearing chamber.
15. The rotating machine of claim 14, further comprising: a
pressurized fluid source in fluid communication with the bearing
chamber; and a pressurized fluid return in fluid communication with
the bearing chamber, the bearing chamber fluidly coupled the
pressurized fluid source to the pressurized fluid return.
16. A method of making a thrust bearing, comprising: defining a top
plate, a thrust plate, and a bump plate; arranging the top plate
about a rotation axis; arranging the thrust plate about the
rotation axis at a location axially offset from the top plate and
orthogonal to the rotation axis; and arranging the bump plate about
the rotation axis at a location axially offset from the thrust
plate, wherein defining the bump plate includes defining a bump
plate annular portion and a plurality of bump plate foil portions,
the bump plate annular portion circumferentially interrupted by
each of the bump plate foil portions, wherein arranging the bump
plate about the rotation axis includes arranging the bump plate
annular portion axially between the bump plate foil portions of the
bump plate and the thrust plate, wherein: the plurality of bump
plate foil portions extend axially from the bump plate annular
portion in a direction axially opposite the top plate; the top
plate has a top plate annular portion and a plurality of top plate
pad portions, wherein the top plate annular portion is
circumferentially interrupted by the plurality of top plate pad
portions, wherein a solid film lubricant coating is conformally
disposed over the top plate annular portion and the plurality of
top plate pad portions; and the thrust plate has a radially inner
periphery and a radially outer periphery with a plurality of ramp
portions defined therebetween, the radially inner periphery and the
radially outer periphery each, except at an anti-rotation feature
on the radial outer periphery, extending continuously about the
rotation axis, the plurality of ramp portions distributed
circumferentially about the thrust plate.
17. The method of claim 16, further comprising: photochemically
etching a metallic sheet to define a top plate annular body;
pressing the top plate annular body to define a top plate annular
portion and a plurality of top plate pad portions, the top plate
annular portion circumferentially interrupted by each of the top
plate pad portions; and coating the top plate annular portion and
the top plate pad portions with a solid film lubricant coating.
18. The method of claim 16, further comprising photochemically
etching a metallic sheet to define a thrust plate annulus.
19. The method of claim 16, further comprising: photochemically
etching a metallic sheet to define a bump plate annular body; and
pressing the bump plate annular body to define the bump plate
annular body interconnecting the plurality of bump plate foil
portions.
20. The method of claim 16, further comprising axially stacking the
thrust plate between the top plate and the bump plate in a bearing
chamber of a rotating machine.
Description
BACKGROUND
[0001] The present disclosure generally relates to rotating
machinery, and more particularly, to thrust bearings for supporting
rotating machinery.
BRIEF DESCRIPTION
[0002] Hydrodynamic thrust bearings rely on relative rotation
between a shaft, typically referred to as a thrust runner, and a
bearing, to generate a non-linear fluid film between the thrust
runner and the bearing. The fluid film forms when the 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, the
fluid typically being air or oil.
[0003] Hydrodynamic thrust bearings commonly include a plurality of
bearing foils, generally referred to as top foils, a plurality of
bump foils, and an annular support plate. The plurality of top
foils and the plurality of bump foils are typically welded to the
annular support plate to form the thrust bearing, which is then
inserted between the shaft bearing. The welding process can be
labor intensive and, because the annular plate is relatively thin,
the welding process can distort the shape of the annular support
plate due to the uneven heating of the annular support plate during
the welding process. The distortions in the annular support plate
in turn alters the fluid film formation between the bearing and the
thrust runner, inhibiting fluid film in certain locations and
decreasing bearing performance.
[0004] Such thrust bearings have generally been satisfactory for
their intended purpose. However, there remains a need in the art
for improved thrust bearings, rotating machinery having thrust
bearing, and methods of making thrust bearings for rotating
machinery.
BRIEF DESCRIPTION
[0005] A thrust bearing arrangement is provided. The 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, the thrust plate orthogonal to the rotation
axis, and a bump plate. The bump plate extends about the rotation
axis and is axially offset from the thrust plate, the bump plate
having a bump plate annular portion and two or more bump plate foil
portions. The bump plate annular portion is circumferentially
interrupted by the two or more bump plate foil portions.
[0006] In addition to one or more of the features described above,
or as an alternative, further embodiments of the thrust bearing
arrangement may include that the top plate has a top plate annular
portion and two or more of top plate pad portions, top plate
annular portion being circumferentially interrupted by the two or
more top plate pad portions.
[0007] In addition to one or more of the features described above,
or as an alternative, further embodiments of the thrust bearing
arrangement may include the top plate annular portion has a
radially inner periphery, the radially inner periphery of the top
plate extending continuously about the rotation axis and at a
singular radial offset from the rotation axis.
[0008] In addition to one or more of the features described above,
or as an alternative, further embodiments of the thrust bearing
arrangement may include that the top plate annular portion has a
radially outer periphery, the radially outer periphery of the top
plate annular portion extending continuously about the rotation
axis and at a singular radial offset from the rotation axis.
[0009] In addition to one or more of the features described above,
or as an alternative, further embodiments of the thrust bearing
arrangement may include that the two or more top plate pad portions
extend axially from the top plate annular portion in a direction
axially opposite the bump plate.
[0010] In addition to one or more of the features described above,
or as an alternative, further embodiments of the thrust bearing
arrangement may include a solid film lubricant coating is
conformally disposed over the top plate annular portion and the
plurality of top plate pad portions.
[0011] In addition to one or more of the features described above,
or as an alternative, further embodiments of the thrust bearing
arrangement may include the thrust plate has a radially inner
periphery and a radially outer periphery with two or more ramp
portions defined therebetween, the radially inner periphery and the
radially outer periphery each extending continuously about the
rotation axis, the two or more ramp portions distributed
circumferentially about the thrust plate.
[0012] In addition to one or more of the features described above,
or as an alternative, further embodiments of the thrust bearing
arrangement may include the bump plate annular portion has a
radially inner periphery, the radially inner periphery of the bump
plate annular portion extending continuously about the rotation
axis and at a singular radial offset from the rotation axis.
[0013] In addition to one or more of the features described above,
or as an alternative, further embodiments of the thrust bearing
arrangement may include the bump plate annular portion has a
radially outer periphery, the radially outer periphery of the bump
plate annular portion extending continuously about the rotation
axis and at a singular radial offset from the rotation axis.
[0014] In addition to one or more of the features described above,
or as an alternative, further embodiments of the thrust bearing
arrangement may include the two or more bump plate foil portions
extend axially from the bump plate annular portion in a direction
axially opposite the top plate.
[0015] In addition to one or more of the features described above,
or as an alternative, further embodiments of the thrust bearing
arrangement may include that the top plate has an anti-rotation
feature, the thrust plate has an anti-rotation feature, and that
the bump plate has an anti-rotation feature.
[0016] In addition to one or more of the features described above,
or as an alternative, further embodiments of the thrust bearing
arrangement may include that the top plate has a top plate annular
body including a top plate annular portion interconnecting two or
more top plate pad portions, the top plate annular body having no
welds.
[0017] In addition to one or more of the features described above,
or as an alternative, further embodiments of the thrust bearing
arrangement may include that the bump plate has a bump plate
annular body including the bump plate annular portion and the two
or more bump plate foil portions, the bump plate annular portion
interconnecting the two or more bump plate foil portions and having
no welds.
[0018] A rotating machine is also provided. The rotating machine
includes a thrust bearing arrangement as described above. The bump
plate has a bump plate annular body including the bump plate
annular portion and the two or more bump plate foil portions, the
bump plate annular portion interconnecting the two or more of bump
plate foil portions and the bump plate annular body having no
welds. The top plate has a top plate annular portion and two or
more top plate pad portions, the top plate annular portion being
circumferentially interrupted by the two or more top plate pad
portions. A stator member is arranged along the rotation axis and
opposing the thrust bearing arrangement and a shaft member is
arranged along the rotation axis and opposes the thrust bearing
arrangement, the shaft member and the stator member defining
therebetween a bearing chamber, and the thrust bearing arrangement
is disposed within the bearing chamber.
[0019] In addition to one or more of the features described above,
or as an alternative, further embodiments of the rotating machine
may include a pressurized fluid source in fluid communication with
the bearing chamber and a pressurized fluid return in fluid
communication with the bearing chamber, the bearing chamber fluidly
coupled the pressurized fluid source to the pressurized fluid
return.
[0020] A method of making a thrust bearing arrangement is
additionally provided. The method includes defining a top plate, a
thrust plate, and a bump plate. The top plate is arranged about a
rotation axis. The thrust plate is arranged about the rotation axis
at a location axially offset from the top plate and orthogonal to
the rotation axis. The bump plate is arranged about the rotation
axis at a location axially offset from the thrust plate. Defining
the bump plate includes defining a bump plate annular portion and a
plurality of bump plate foil portions, the bump plate annular
portion circumferentially interrupted by each of the bump plate
foil portions. Arranging the bump plate about the rotation axis
includes arranging the bump plate annular portion axially between
the bump plate foil portions of the bump plate and the thrust
plate.
[0021] In addition to one or more of the features described above,
or as an alternative, further embodiments of the method may include
photochemically etching a metallic sheet to define a top plate
annular body, pressing the top plate annular body to define a top
plate annular portion and a plurality of top plate pad portions,
the top plate annular portion circumferentially interrupted by each
of the top plate pad portions; and coating the top plate annular
portion and the top plate pad portions with a solid film lubricant
coating.
[0022] In addition to one or more of the features described above,
or as an alternative, further embodiments of the method may include
photochemically etching a metallic sheet to define a thrust plate
annulus.
[0023] In addition to one or more of the features described above,
or as an alternative, further embodiments of the method may include
photochemically etching a metallic sheet to define a bump plate
annular body, and pressing the bump plate annular body to define
the bump plate annular body interconnecting the plurality of bump
plate foil portions.
[0024] In addition to one or more of the features described above,
or as an alternative, further embodiments of the method may include
axially stacking the thrust plate between the top plate and the
bump plate in a bearing chamber of a rotating machine.
[0025] Technical effects of the present disclosure include thrust
bearings without the structural distortion that can result from
welding. The present disclosure also provides thrust bearings with
relatively long service life, exhibit relatively uniform wear
during service, and which are relatively inexpensive in comparison
to thrust bearings assembled using welding techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The following descriptions should not be considered limiting
in any way. With reference to the accompanying drawings, like
elements are numbered alike:
[0027] FIG. 1 is a perspective view of a rotating machine
constructed in accordance with the present disclosure, showing a
thrust bearing arrangement disposed between a shaft member and a
stator member a rotation axis;
[0028] FIG. 2 is an exploded view of a portion of the rotating
machine of FIG. 1 including the thrust bearing arrangement, showing
a top late, a thrust pate, a bump plate the thrust bearing
arrangement according to an illustrative embodiment of the thrust
bearing arrangement;
[0029] FIG. 3 is a plan view of the top plate of the thrust bearing
arrangement of FIG. 1, showing a top plate annular body of the top
plate with a top plate annular portion extending about the rotation
axis and a plurality of top plate foil portions circumferentially
distributed about the rotation axis;
[0030] FIG. 4 is a plan view of the thrust plate of the thrust
bearing arrangement of FIG. 1, showing a thrust plate annulus of
the thrust plate extending about the rotation axis;
[0031] FIG. 5 is a perspective view of the bump plate of the thrust
bearing arrangement of FIG. 1, showing a bump plate annular body
having a bump plate annular portion extending about the rotation
axis and a plurality of bump plate foil portions circumferentially
distributed about the rotation axis;
[0032] FIG. 6 is a partial cross-sectional view of the bearing
arrangement of FIG. 1, showing the top plate annular portion of the
top plate circumferentially interrupted by a top plate pad portion
and the bump plate annular portion of the bump plate
circumferentially interrupted by a bump plate foil portion; and
[0033] FIG. 7 is a block diagram of a method of making a thrust
bearing arrangement according to the present disclosure, showing
operations of the method according to an illustrative and
non-limiting embodiment of the present disclosure.
DETAILED DESCRIPTION
[0034] Reference will now be made to the drawings wherein like
reference numerals identify similar structural features or aspects
of the subject disclosure. For purposes of explanation and
illustration, and not limitation, a partial view of an exemplary
embodiment of a thrust bearing arrangement in accordance with the
disclosure is shown in FIG. 1 and is designated generally by
reference character 100. Other embodiments of thrust bearing
arrangements, rotating machines having thrust bearing arrangements,
and methods of making thrust bearing arrangements in accordance
with the present disclosure, or aspects thereof, are provided in
FIGS. 2-7, as will be described. The systems and methods described
herein can be used for supporting rotating structures in rotating
machines, such as turbines and compressors in air cycle machines,
though the present disclosure is not limited to turbines and
compressors, or to air cycle machines in general.
[0035] With reference to FIG. 1, a rotating machine 10, e.g., a
compressor or a turbine for an air cycle machine, is shown. The
rotating machine 10 includes a shaft member 12, a stator member 14,
and the thrust bearing arrangement 100. The rotating machine 10
also includes a pressurized fluid source 16, a pressurized fluid
return 18, and a pressurized fluid 20. In certain embodiments the
pressurized fluid 20 can be air that is returned to the pressurized
fluid source 16, e.g., in embodiments where the rotating machine 10
is an air cycle machine.
[0036] The stator member 14 is arranged along a rotation axis 22
and has a thrust bearing face 24. The shaft member 12 has a fluid
face 26, is disposed along the rotation axis 22 and axially opposes
the stator member 14 such that the fluid face 26 and the thrust
bearing face 24 define therebetween one another a bearing chamber
28. The bearing chamber 28 is bounded by the thrust bearing face 24
of the stator member 14 and the fluid face 26 of the shaft member
12 and houses therein the thrust bearing arrangement 100. The
pressurized fluid source 16 is in fluid communication with the
pressurized fluid return 18 such that the pressurized fluid 20 at
least partially occupies the bearing chamber 28, the pressurized
fluid return 18 thereby fluidly coupled to the pressurized fluid
source 16.
[0037] As will be appreciated by those of skill in the art in view
of the present disclosure, the thrust bearing arrangement 100 can
support the shaft member 12 for rotating relative to the stator
member 14 by generating a hydrodynamic fluid film of sufficient
pressure to axially separate the thrust bearing arrangement 100
from the shaft member 10. Axially separation allows the shaft
member 12 to rotate relative to the stator member 14 with little
friction (or substantially no friction). A fluid film can be
generated from the pressurized fluid 20, for example, by coupling
discrete hydrodynamic foil structures on a surface axially opposing
the shaft member 12 with welds, and by further coupling discrete
bump foil structures on a surface opposing the stator member 14
with additional welds.
[0038] As will also be appreciated by those of skill in the art in
view of the present disclosure, the residual stress build-up
resulting from welding, warpage associated with heating during
welding, and uneven load distribution on the hydrodynamic foil tops
due to the welding can accelerate wear of the thrust bearing
arrangement. Further, the welding process itself can be relatively
labor intensive, adding cost to the thrust bearing arrangement. To
limit (or eliminate entirely) the tendency of uneven wear and/or
limit cost the thrust bearing arrangement 100 is provided.
[0039] With reference to FIG. 2, the thrust bearing arrangement 100
is shown. The thrust bearing arrangement 100 includes a top plate
102 extending about the rotation axis 22, a thrust plate 104
extending about the rotation axis 22 and axially offset from the
top plate 102, and a bump plate 106. The thrust plate 104 is
orthogonal relative to the rotation axis 22. The bump plate 106
extends about the rotation axis 22, is axially offset from the
thrust plate 104, and has a bump plate annular portion 112 and a
plurality of bump plate foil portions 114. The bump plate annular
portion 112 is circumferentially interrupted by the plurality of
bump plate foil portions 114.
[0040] With reference to FIGS. 3 and 6, an example of the top plate
102 is shown. The top plate 102 includes a top plate annular body
116. The top plate annular body 116 has a top plate annular portion
118 and a plurality of top plate pad portions 120. The top plate
annular portion 118 is circumferentially interrupted by the
plurality of top plate pad portions 120, the top plate annular
portion 118 interconnecting circumferentially adjacent top plate
pad portions 120. It is contemplated that the top plate pad
portions 120 and the top plate annular portion 118 be formed from a
singular piece of sheet stock, the top plate pad portions 120 and
the top plate annular portion 118 thereby being monolithic in
arrangement. This avoids the need to fix, e.g., via welding, pads
to an underlying plate structure, simplifying the fabrication of
the top plate 102. In certain embodiments the top plate 102 is
formed from a pressed sheet of metal, such as carbon or stainless
steel by way of non-limiting example.
[0041] The top plate annular portion 118 has a radially inner
periphery 122 and a radially outer periphery 124. The radially
inner periphery 122 extends circumferentially about the rotation
axis 22 continuously at a singular radial offset 126 from the
rotation axis 22. The radially outer periphery 124 extends
circumferentially about the radially inner periphery 122 and is
disposed radially outward of the radially inner periphery 122. In
the illustrated embodiment the radially outer periphery 124 of the
top plate annular portion 118 extends continuously about the
rotation axis 22 at a singular radial offset 128. It is
contemplated that the top plate annular portion 118 defines an
anti-rotation feature 130 configured to fix the top plate 102 in
rotation about the rotation axis 22 relative to the shaft member 12
(shown in FIG. 1) or the stator member 14 (shown in FIG. 1), as
suitable for a given application. In certain embodiments the
anti-rotation feature 130 allows for fixation of the top plate 102
to a stator, e.g., the stator member 14 (shown in FIG. 1). In
accordance with certain embodiments, the anti-rotation feature 130
also allows for error-proofing the assembly of the thrust bearing
arrangement 100 (shown in FIG. 1). It is also contemplated that the
running torque exerted by the rotating structure, e.g., the shaft
structure 12 (shown in FIG. 1) supported by the thrust bearing
arrangement 100 be reacted by forces provided by fixation of the
anti-rotation feature on each of foils forming the thrust bearing
assembly, e.g., the anti-rotation feature 130 (shown in FIG. 3),
the anti-rotation feature 154 (shown in FIG. 4), and the
anti-rotation feature 170 (shown in FIG. 5).
[0042] The top plate pad portions 120 extend axially from the top
plate annular portion 118 and are distributed circumferentially
about the rotation axis 22. In this respect top plate annular
portion 118 has a shaft-facing surface 132 and an opposite thrust
plate-facing surface 134, the shaft-facing surface 132 opposing the
shaft member 12 (shown in FIG. 1), and thrust plate-facing surface
134 facing the thrust plate 104 (shown in FIG. 2), and the top
plate pad portions 120 each extending continuously, i.e., with no
gap therebetween about a periphery of the respective top plate pad
portions 120 and the top plate annular portion 118, in the
direction of the shaft member 12. It is contemplated that surfaces
136 of the top plate pad portions 120 are arranged axially between
the shaft member 12 and shaft-facing surface 132 of the top plate
annular portion 118. In the illustrated embodiments a solid film
lubricant coating 138 is disposed, e.g., conformally disposed, over
the shaft-facing surface 132 of the top plate annular body 116,
limiting wear during startup and shutdown of the rotating machine
10.
[0043] With reference to FIGS. 4 and 6, the thrust plate 104 is
shown. The thrust plate 104 includes a thrust plate annulus 140
with a plurality of ramp portions 176 distributed about the thrust
plate annulus 104. The thrust plate annulus 140 has a radially
inner periphery 142, a radially outer periphery 144, a top foil
plate-facing surface 146, and a bump foil plate-facing surface 148.
The radially inner periphery 142 extends continuously about the
rotation axis 22 and is radially offset therefrom by an inner
periphery radial offset 150. The radially outer periphery 144
extends continuously about the rotation axis 22, is located
radially outward of the radially inner periphery 142, and is
radially offset from the rotation axis 22 by an outer periphery
radial offset 152. It is contemplated that the radially outer
periphery 144 extend circumferentially about the radially inner
periphery 142, the thrust plate annulus 140 thereby being
monolithic and continuous therebetween.
[0044] The top foil plate-facing surface 146 axially opposes the
top plate 102 (shown in FIG. 2) and extends continuously between
the radially inner periphery 142 and the radially outer periphery
144 of the thrust plate annulus 140. The bump foil plate-facing
surface 148 extends continuously between the radially inner
periphery 142 and the radially outer periphery 144, axially opposes
the bump plate 106, and extends continuously between the radially
inner periphery 142 and the radially outer periphery 144 of the
thrust plate annulus 140. It is contemplated that the thrust plate
annulus 140 be formed from a metallic sheet, such as carbon or
stainless steel by way of non-limiting example. In certain
embodiments the thrust plate 104 can include an anti-rotation
feature 154, fixing the thrust plate 104 relative to the shaft
member 12 (shown in FIG. 1) or the stator member 14 (shown in FIG.
1), simplifying assembly of the thrust bearing arrangement 100
(shown in FIG. 1).
[0045] The plurality of ramp portions 176 define a portion of the
top plate-facing surface 146 and are arranged axially between the
top foil plate 102 and the thrust plate annulus 140. It is
contemplated that the ramp portions 176 vary in axial height
circumferentially, the plurality of ramp portions 176 thereby
providing hydrodynamic lift within the bearing arrangement 100
(shown in FIG. 1). The contour of the plurality of ramp portions
176 can be defined, for example, using a photochemical etching
technique by way of non-limiting example.
[0046] With reference to FIGS. 5 and 6, the bump plate 106 is
shown. The bump plate 106 has a bump plate annular body 156. The
bump plate annular body 156 has the bump plate annular portion 112,
the plurality of bump plate foil portions 114, a thrust
plate-facing surface 158, and a stator member-facing surface 160.
The bump plate annular portion 112 is circumferentially interrupted
by the plurality of bump plate foil portions 114, the bump plate
annular portion interconnecting circumferentially adjacent bump
plate foil portions 114. The bump plate annular portion 112 has a
radially inner periphery 162 and a radially outer periphery 164. In
certain embodiments the bump plate 106 is formed from a pressed
metal sheet, such as a carbon or stainless-steel sheet member by
way of non-limiting example.
[0047] The radially inner periphery 162 of the bump plate annular
portion 112 extends circumferentially about the rotation axis 22,
and in the illustrated embodiment extends continuously about the
rotation axis 22 without interruption at a singular inner periphery
radial offset 166. The radially outer periphery 164 of the bump
plate annular portion 112 extends circumferentially about the
radially inner periphery 162 and is disposed radially outward of
the radially inner periphery 162. In the illustrated embodiment the
radially outer periphery 164 of the bump plate annular body 156
extends continuously about the rotation axis 22 at a singular outer
periphery radial offset 168. In the illustrated embodiment the bump
plate 106 has an anti-rotation feature 170, which fixes the bump
plate 106 to one of the shaft member 12 or the stator member 14
and/or simplifies the assembly of the thrust bearing arrangement
100 (shown in FIG. 1).
[0048] The thrust plate-facing surface 158 of the bump plate 106
opposes the thrust plate 104 along the rotation axis 22. The stator
member-facing surface 160 is located on a side of the bump plate
annular body 156 axially opposite the thrust plate-facing surface
158 and axially opposes the stator member 14. The bump plate foil
portions 114 extend from the bump plate annular portion 112, i.e.,
extending axially from the stator member-facing surface 160, and
are distributed circumferentially about the rotation axis 22. In
this respect bump plate foil portions 114 are arranged axially
between the stator member-facing surface 160 and the stator member
14. It is contemplated that bump plate foil portions 114 each
define hydrodynamic features 174, e.g., corrugations, configured to
generate a hydrodynamic film between the top plate 102 (shown in
FIG. 2) and the shaft member 12 (shown in FIG. 1). It is also
contemplated that the bump plate foil portions 114 each extend
continuously, i.e., with no gap therebetween about a periphery 172
of the respective bump plate foil portions 114 and the bump plate
annular portion 112 in the direction of the stator member 14. This
avoids the need to fix, e.g., via welding, discrete bump foil
structures to a supporting structure, simplifying the fabrication
of the bump plate 106.
[0049] In certain embodiments each of the bump plate foil portions
114 can be axially registered with a respective one of the
plurality of top plate pad portions 120 (shown in FIG. 3). In
accordance with certain embodiments each of the bump plate foil
portions 114 can be circumferentially offset from one of the
plurality of top plate pad portions 120. It is also contemplated
that number of top plate pad portions 120 defined by the bump plate
106 can be equivalent to the number of top plate pad portions 120.
In further embodiments the bearing arrangement can include seven
(7) bump plate foil portions 114.
[0050] With reference to FIG. 7, a method 200 of making a thrust
bearing arrangement, e.g., the thrust bearing arrangement 100
(shown in FIG. 1), is shown. The method 200 of making the thrust
bearing generally includes defining a top plate, e.g., the top
plate 102 (shown in FIG. 2), as shown with box 210. The method 200
also includes defining a thrust plate, e.g., the thrust plate 104
(shown in FIG. 2), as shown with box 220. The method 200
additionally includes defining a bump plate having a plurality of
bump plate ramp portions, e.g., the bump plate 106 (shown in FIG.
2), as shown with box 230.
[0051] Defining the top plate includes defining a top plate body,
e.g., the top plate annular body 116 (shown in FIG. 3), as shown
with box 210. It is contemplated that the top plate body be formed
from metal sheet, e.g., foil, using a photochemical etching
technique, as shown with box 212. It is contemplated that the top
plate body can be formed from metal sheet using a laser etch
technique or a stamping process, as shown with box 214 and box 216.
Photochemically etching the top plate body with a photochemical
etch technique can simplify the fabrication process by reducing (or
eliminating entirely) the need to deburr or remove slag from the
top plate body subsequent to forming the top plate body.
[0052] Once the top plate body is defined a solid film lubricant
coating is conformally disposed over the top plate body, e.g., the
solid film lubricant coating 138 (shown in FIG. 3). The coated top
plate body is thereafter pressed, i.e. in a pressing operation, to
define a top plate annular portion, e.g., the top plate annular
portion 118 (shown in FIG. 3), circumferentially interrupted by a
plurality of top plate pad portions, e.g., the top plate pad
portions 120 (shown in FIG. 3), as shown with box 219. As will be
appreciated by those of skill in the art in view of the present
disclosure, pressing the top plate body to define the plurality of
top plate pad portions and the top plate annular portion eliminates
the need to weld discrete pad structures to an underlying support
structure, limiting (or eliminating entirely) residual stress and
warpage associated with welding techniques.
[0053] Defining the thrust plate includes defining a thrust plate
body, e.g., the thrust plate annulus 140 (shown in FIG. 4), as
shown with box 220. It is contemplated that the thrust plate body
be formed from metal sheet, e.g., foil, using a photochemical
etching technique, as shown with box 222. It is contemplated that
the top plate body can be formed from metal sheet using a laser
etch technique or a stamping process, as shown with box 224 and box
226. As above, photochemically etching the thrust plate body with a
photochemical etch technique can also simplify the fabrication
process of the thrust plate by reducing (or eliminating entirely)
the need to deburr or remove slag from the trust plate body
subsequent to forming the thrust plate body.
[0054] Defining the bump plate includes defining a bump plate body,
e.g., the bump plate annular body 156 (shown in FIG. 5), as shown
with box 230. It is contemplated that the bump plate body be formed
from metal sheet, e.g., foil, using a photochemical etching
technique, as shown with box 232. It is contemplated that the bump
plate body can be formed from metal sheet using a laser etch
technique or a stamping process, as shown with box 234 and box 236.
Photochemically etching the bump plate body with a photochemical
etch technique can simplify the fabrication process by reducing (or
eliminating entirely) the need to deburr or remove slag from the
bump plate body subsequent to forming the bump plate body.
[0055] Once the bump plate body is formed the bump plate body is
thereafter pressed, i.e. in a pressing operation, to define a bump
plate annular portion, e.g., the bump plate annular portion 112
(shown in FIG. 5), circumferentially interrupted by a plurality of
bump plate pad portions, e.g., the bump plate foil portions 114
(shown in FIG. 5), as shown with box 236. As will be appreciated by
those of skill in the art in view of the present disclosure,
pressing the bump plate body to define the plurality of bump plate
foil portions and the bump plate annular portion eliminates the
need to weld discrete hydrodynamic foil structures to an underlying
support structure, limiting (or eliminating entirely) warpage and
residual stress within the top plate that can be associated with
welding techniques. In addition, hydrodynamic structures, e.g., the
hydrodynamic features 174 can also be defined in the pressing
operation, simplifying fabrication by eliminating the need for the
hydrodynamic structures to be formed in a separate operation.
[0056] As shown with bracket 240, a thrust bearing arrangement,
e.g., the thrust bearing arrangement 100 (shown in FIG. 1), can be
formed using the top plate, the thrust plate, and the bump plate.
For example, the top plate can be arranged about a rotation axis,
e.g., the rotation axis 22 (shown in FIG. 1), as shown with box
242, the thrust plate arranged about the rotation axis such that
the thrust plate is orthogonal relative to the rotation axis, as
shown with box 244, and the bump plate arranged about the rotation
axis at a location axially offset from the thrust plate and on a
side the thrust plate opposite the top plate, as shown with box
246. Arranging the top plate and the bump plate on axially opposite
sides of the thrust plate allows the thrust bearing arrangement to
serve as a drop-in replacement for a weldment-type thrust bearing,
limiting the need to alter the configuration of a rotating machine
incorporating the thrust bearing arrangement. It is contemplated
that the top plate, the thrust plate, and the bump be arranged
within a bearing chamber of a rotating machine, e.g., the bearing
chamber 28 (shown in FIG. 1) or the rotating machine 10 (shown in
FIG. 1). For example, the arrangement can be established in a
stacking operation by aligning each of the top plate, the thrust
plate.
[0057] The term "about" is intended to include the degree of error
associated with measurement of the particular quantity based upon
the equipment available at the time of filing the application. The
terminology used herein is for the purpose of describing particular
embodiments only and is not intended to be limiting of the present
disclosure. As used herein, the singular forms "a", "an" and "the"
are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, element components, and/or groups thereof.
[0058] While the present disclosure has been described with
reference to an exemplary embodiment or embodiments, 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 present disclosure. In
addition, many modifications may be made to adapt a particular
situation or material to the teachings of the present disclosure
without departing from the essential scope thereof. Therefore, it
is intended that the present disclosure not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this present disclosure, but that the present
disclosure will include all embodiments falling within the scope of
the claims.
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