Abstract:
A vane pump is disclosed for use with gas turbine engines adapted and configured to provide a failure mode similar to that of a traditional gear pump. The vane pump includes a pump housing, a cam member, a cylindrical rotor member and a mechanism for communicating a high pressure fluid from the discharge arc region to the inlet arc region when the tip surface of each vane element has experienced a predetermined amounted of wear so as to prevent pump startup. The wearing of the tip surface of each vane element resulting from the slideable engagement with the circumferential surface of the pumping cavity.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 09/741,524, filed Dec. 20, 2000, and claims priority to U.S. Provisional Patent Application No. 60/236,293, filed Sep. 28, 2000, both of which are herein incorporated by reference in their entirety to the extent they are not inconsistent with this disclosure. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The subject invention relates to fuel pumps for gas turbine engines, and more particularly, to vane pumps which are used in applications that require high operational reliability and a predicted failure mode.  
           [0004]    2. Background of the Related Art  
           [0005]    Vane pumps are being developed within the aerospace industry as an alternative to traditional gear pumps. An example of a variable displacement vane pump is disclosed in U.S. Pat. No. 5,545,014 to Sundberg et al., the disclosure of which is herein incorporated by reference in its entirety to the extent that it does not conflict with the present disclosure.  
           [0006]    Vane pumps traditionally include, among other things, a housing, a cam member and a rotor supported within the housing by axially opposed journal bearings. The housing defines an interior chamber, a fluid inlet and a fluid outlet and the cam member and rotor are disposed within the interior chamber. The cam member has a central bore which defines the circumferential boundary of the internal pumping chamber. Mounted for rotational movement within the central bore of the cam member, is a rotor supported by axial opposed journal bearings. The rotor element has circumferentially spaced apart slots machined therein which support corresponding radially movable vane elements.  
           [0007]    Variable displacement vane pumps differ from other vane pumps, such as fixed displacement vane pumps, in that the cam member pivots about a fulcrum aligned with the vertical centerline of the pump, thereby adjusting its position with respect to the rotor. This adjustment allows the relative volumes of the inlet and discharge buckets to be changed and thereby vary the displacement capacity of the pump.  
           [0008]    In a single rotation, the vanes of the rotor element of the pump traverse at least four distinct arcuate regions which make up the 360 degree revolution. The first region is the inlet arc segment in which fluid is received into the pumping chamber and over this region the bucket volume increases. The second region is the discharge arc segment in which pressurized fluid is discharged from the pumping chamber and over this region the bucket volume decrease. Lastly, seal arc segments separate the inlet and discharge arc segments and represent the regions through which the bucket volume remains substantially constant.  
           [0009]    In operation, fluid at a first pressure is fed into the pumping chamber through the housing inlet, and into the space defined between adjacent vane elements, known as the bucket. In positive displacement vane pumps, as the vane elements rotate within the pumping chamber from the inlet region to the outlet region, the configuration of the cam member causes the vanes to retract within the corresponding slots. This causes the volume defined by the bucket to decrease. Since the amount of fluid received into an inlet bucket is greater than that contained within the corresponding discharge bucket, a fluid volume equivalent in size to the volumetric difference is discharged or displaced through the outlet port at a pressure equal to the downstream pressure which must be overcome.  
           [0010]    Typically, pumping pressures and velocities are so high within the pump housing that the use of heavy, high wear resistant materials for the cam member and the vane elements becomes necessary to handle the wear which is caused by these high levels of pressure and velocity.  
           [0011]    Prior variable displacement vane pumps are illustrated in U.S. Pat. No. 5,545,014 to Sundberg et al. and U.S. Pat. No. 5,833,438 to Sundberg. U.S. Pat. No. 5,545,014 discloses a durable, single action, variable displacement vane pump capable of undervane pumping and a pressure balancing method. U.S. Pat. No. 5,833,438 to Sundberg teaches a variable displacement vane pump having a durable rotor member with journal ends at each side of a large diameter central vane section and a mechanism for confining the high pressure within the cam member and thereby preventing axial pressure leakage along the length of the rotor member. The disclosure contained within these patent is hereby incorporated by reference in their entirety to the extent it does not conflict with the present disclosure.  
           [0012]    The advantages of variable displacement pumps over conventional pumps, namely gear pumps, is that they solve the problem where excess heat generation becomes a crucial impediment to pump performance. Also, a variable displacement vane pump can be used to eliminate certain fuel flow metering components by utilizing the pump as the metering device.  
           [0013]    One of the disadvantages associated with vane pump technology is the failure mode. As a result, there is a reluctance to implement this technology in applications, such as high performance aircraft, that require high operational reliability and a predicted failure mode. With a conventional gear pump, the failure mechanism is well known. Typically as the pump degrades, the performance drops off far enough so that eventually one cannot start the engine, thus a safe failure occurs. With a vane pump, however, as the vanes wear away due to contact with the cam surface, the cantilevered load that the pressure puts on each vane can become so high that a catastrophic failure of a vane can occur during pump operation and effectively destroys the whole pumping system without warning. In an applications such as helicopter fuel systems, this type of failure can cause damage to the control system and engine. In order to prevent such an occurrence, the vane pump must be inspected and maintained frequently.  
           [0014]    In view of the foregoing, a need exists for an improved vane pump which resembles the failure mode of a gear pump by “tracking” wear of the vanes, and disabling the engine from starting after a certain level of wear is attained.  
         SUMMARY OF THE INVENTION  
         [0015]    The subject application is directed to vane pumps for use with gas turbine engines which include a mechanism for altering the failure mode of the pump thereby preventing an operational failure. In a preferred embodiment, the vane pump includes a pump housing, a cam member, a rotor member and a mechanism for communicating a high pressure fluid from the discharge arc region to the inlet arc region so as to prevent pump start-up when a predetermined wear state has been reached.  
           [0016]    The pump housing typically includes a cylindrical interior chamber which defines a central axis through which a vertical centerline and a horizontal centerline extend. The cam member is mounted for pivotable movement within the interior chamber of the pump housing about a fulcrum aligned with the vertical centerline of the interior chamber. The cam member has a bore extending therethrough which defines a circumferential surface of a pumping cavity. The circumferential surface of the pumping cavity includes a discharge arc segment, an inlet arc segment and seal arc segments separating the inlet arc segment and the discharge arc segments from one another.  
           [0017]    The cylindrical rotor member is mounted for rotational movement within the bore of the cam member about the central axis of the interior chamber. The rotor member has a central body portion with first and second axially opposed end surfaces and a plurality of circumferentially spaced apart radially extending vane slots formed therein. Each vane slot supports a corresponding vane element mounted for radial movement therein. Each of the vane elements have a radially outer tip surface which is adapted for slideably engaging the circumferential surface of the pumping cavity and a radially inner undervane portion which is positioned within each vane slot.  
           [0018]    The mechanism for communicating a high pressure fluid from the discharge arc region to the inlet arc region so as to prevent pump start-up activates when the tip surface of each vane element has worn a predetermined amounted with respect to the undervane portion of each vane element.  
           [0019]    In a preferred embodiment, the mechanism for communicating a high pressure fluid from the discharge arc region to the inlet arc region when the tip surface of each vane element has worn a predetermined amount includes arcuate channels formed in the first end surface of the body portion of the rotor member. The arcuate channels each extend between each vane slot. It is envisioned that the arcuate channels are spaced from the central axis by a radial distance and the radial distance defines the predetermined amount of wear.  
           [0020]    In an alternate embodiment, the means for communicating a high pressure fluid from the discharge arc region to the inlet arc region when the tip surface of each vane element has worn a predetermined amount includes arcuate channels formed in the second end surface of the body portion of the rotor member  
           [0021]    It is presently preferred that the predetermined amount of wear is reached when the undervane portion of each vane element at a point in the pumping cavity is positioned radially outward of the arcuate channels formed in the body portion of the rotor. As a result of this relative positioning, fluid is allowed to communicate from the discharge arc segment to the inlet arc segment of the pumping cavity.  
           [0022]    The circumferential surface of the pump cavity includes a discharge arc segment of about 150 degrees, a first seal arc segment of about 30 degrees, an inlet arc segment of about 150 degrees and a second seal arc segment of about 30 degrees.  
           [0023]    It is further envisioned that first and second axially spaced apart end plates are disposed within the interior chamber of the pump housing. Each end plate has a first surface which is adjacent to the rotor member and forms an axial end portion of the pumping cavity. Each end plate is spaced from the rotor member so as to allow frictionless rotation of the rotor member within the pumping cavity. Preferably the end plates include a mechanism associated with the first surface of each end plate for communicating fluid from the discharge arc segment of the pumping cavity to the undervane portion of each vane element when each vane element passes through the discharge and seal arc segments. Additionally, the first surface of each end plate includes a mechanism for communicating fluid from the inlet arc region of the pumping cavity to the undervane portion of each vane element when each vane element passes through the inlet arc segment as the rotor member rotates about the central axis.  
           [0024]    It is presently envisioned that the rotor member further includes a plurality of substantially axial fluid passages formed in the central body portion of the rotor. Each passage is positioned between the plurality of circumferentially spaced apart radial vane slots and provides a path through the rotor body portion for fluid to communicate axially from the pumping cavity to the first and second end plate.  
           [0025]    The subject application is also directed to a vane pump which includes, among other things, a pump housing a cam member, a rotor member. The rotor member being substantially cylindrical and mounted for rotational movement within the bore of the cam member about the central axis of the interior chamber. The rotor member includes a central body portion with first and second axially opposed end surfaces and a plurality of circumferentially spaced apart radially extending vane slots formed therein.  
           [0026]    It is envisioned that each vane slot supports a corresponding vane element mounted for radial movement therein. Each vane element has a radially outer tip surface adapted for slideably engaging the circumferential surface of the pumping cavity and a radially inner undervane portion within each vane slot. Preferably, the first end surface of the body portion has arcuate channels formed therein which extend between each vane slot. The arcuate channels providing a path for high pressure fluid to leak from the discharge arc segment to the inlet arc segment of the pumping cavity when each vane tip surface has worn such that the undervane portion is positioned radially outward of the arcuate channels.  
           [0027]    In a preferred embodiment, the arcuate channels are spaced from the central axis by a radial distance whereby the radial distance defines an amount of allowable vane tip surface wear which can occur before high pressure fluid can leak from the discharge arc segment to the inlet arc segment of the pumping cavity.  
           [0028]    The present application is also directed to a vane pump which includes a pump housing, a cam member, a rotor member, a leak path, first and second axially spaced apart end plates. The leak path communicates fluid from the discharge arc region to the inlet arc region when the cam member is in a start-up position and each undervane portion is positioned radially outward of the leak path. It is envisioned that the leak path includes arcuate channels formed in the first end surface of the body portion of the rotor member which extend between each vane slot.  
           [0029]    Those skilled in the art will readily appreciate that the inventive aspects of this disclosure can be applied to any type of vane pump, such as fixed or variable displacement vane pumps. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0030]    So that those having ordinary skill in the art to which the present application appertains will more readily understand how to make and use the same, reference may be had to the drawings wherein:  
         [0031]    [0031]FIG. 1 is a cross-sectional view of a variable displacement vane pump constructed in accordance with a preferred embodiment of the present application which includes a pump housing, a pivotal cam member, and a rotor member with associated vane elements;  
         [0032]    [0032]FIG. 2 is a side elevational view in cross-section of the vane pump of FIG. 1 illustrating the manner in which fluid is received into and discharged from the pumping chamber;  
         [0033]    [0033]FIG. 3 is a side elavational view of the face of the end plate of the pump of FIG. 1 illustrating a series of channels and recesses formed therein;  
         [0034]    [0034]FIG. 4 is a cross-sectional view of the rotor of FIG. 2, the rotor having arcuate recesses or channels cut in each end of the body portion between adjacent vane slots;  
         [0035]    [0035]FIG. 5 is a side elevational view taken in cross-section of the rotor member of the vane pump of FIG. 1 illustrating arcuate channels formed in an end of the rotor for allowing high pressure fuel to communicate with the low pressure side of the sealing arc when a pre-established vane wear state has been reached; and  
         [0036]    [0036]FIG. 6 is an enlarged localized cross-sectional view of a variable displacement vane pump in the worn state wherein fuel communicates from the high pressure side of the pumping chamber to the low pressure side of the sealing arc.  
         [0037]    These and other features of the vane pump of the present application will become more readily apparent to those having ordinary skill in the art form the following detailed description of the preferred embodiments. 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0038]    Referring now to the drawings wherein like reference numerals identify similar structural aspects of the subject invention, there is illustrated in FIG. 1 a variable displacement vane pump constructed in accordance with a preferred embodiment of the subject application and designated generally by reference numeral  10 . Vane pump  10  includes a pump housing  12  defining an interior chamber which supports a cam member  14  and a rotor member  16 . Rotor member  16  includes a plurality of radially extending slots  17 . Each slot is configured to support a corresponding vane element  18 . Cam member  14  is mounted for pivotal movement within pump housing  12  about a pivot pin  20  that defines a fulcrum, so as to vary the displacement of vane pump  10 . Cam member  14  includes a one-piece body that defines a bore  22  forming a cam chamber. The circular bore  22  defines a smooth continuous circumferential surface  24  of the pumping cavity, making continuous contact with the outer tip surfaces  21  of each vane element  18 . A lever  25  extends from the body of cam member  14  and is pivotably connected to actuation piston assembly  15 , for varying the position of the cam member  14  relative to the rotor member  16 .  
         [0039]    As illustrated in FIG. 1, each vane element  18  fits snugly within a corresponding slot  17  and functions like a piston as it is depressed radially inwardly during movement of the rotor member  16  through the high pressure discharge arc region  62  (FIG. 3) of the pumping chamber. Each slot  17  has a radially inner undervane cavity  19  defining an area that is open to low inlet pressure when the vane element  18  is in the inlet arc region  60  ( FIG. 3) of the pumping chamber, and to high discharge pressure when the vane element  18  is in the discharge arc region  62  of the pumping chamber and the seal arc regions  64   a  and  64   b  (FIG. 3) of the pumping chamber. The manner in which pressurized fluid is communicated to the undervane cavity will be described in more detail herein below with respect to FIG. 3.  
         [0040]    Referring to FIG. 2, vane pump  10  further includes an inlet region  50  for admitting low pressure fluid into the pumping chamber and a discharge region  52  for discharging high pressure fluid from the pumping chamber. A main drive shaft  32  extends through the interior chamber of pump housing  12  along the longitudinal axis thereof for driving a central shaft member  34 . Shaft member  34  is supported for rotation by opposed journal bearings  36   a  and  36   b,  and is keyed to rotor member  16  for imparting rotational motion thereto.  
         [0041]    Opposed sideplates  40  and  42 , which are disposed within the interior chamber, form a sealed cavity between cam member  14  and rotor member  16 , and provide inlet and discharge ports for the cavity. Axial spacer  30  is supported within the housing  12 , between sideplates  40  and  42 , and has a thickness that is slightly greater than the thickness of cam member  14 . This allows the sideplates  40  and  42  to be tightly clamped against the spacer  30  by a plurality of threaded fasteners (not shown) while allowing small gaps to remain between the cam member  14  and the sideplates to reduce or eliminate friction therebetween.  
         [0042]    Referring now to FIG. 3, surface  44  of side plate  40  is disposed adjacent rotor member  16 . The 360 degree pumping chamber includes an inlet arc region  60 , a discharge arc region  62  and sealing arc regions  64   a  and  64   b  positioned between the inlet and discharge arc regions  60  and  62 . The inlet arc region  60  represents the portion of the pumping chamber in which the volume contained between adjacent vane elements (i.e., within the buckets) increases and low pressure fluid is received into the pumping chamber. The discharge arc region  62  is the portion of the pumping chamber in which the volume contained between adjacent vane elements decreases. In the seal arc regions  64   a  and  64   b,  the volume remains substantially constant.  
         [0043]    When the rotor  16  rotates within the pumping chamber, the centrifugal force created thereby imparts a radially outward force on each vane elements  18 . In addition, the pressurized fluid contained within adjacent buckets imparts a radially inward force on each adjacent vane element  18 . Often, the opposed forces which are applied to each vane element  18  are not balanced. As a result, the vane tip  21  of each vane  18  is either subjected to excessive wear due to a net radially outward force or fluid leaks from within the bucket due to a net radially inward force. This reduces pumping efficiency. An ideal pump operating condition occurs when the pressure applied to the vane elements is balanced and the vane elements “float” within the slots defined in the rotor. This condition results in minimum wear to the vane tips and minimizes the pressure losses caused by the lack of contact between the vane tips and the cam member.  
         [0044]    Pump  10  is adapted and configured to correct the unbalanced vane condition by applying pressure to the undervane portion  23  of each vane element  18 . More specifically, low pressure from within each bucket traversing the inlet region  60  is supplied to the undervane portion  23  of vane elements  18  within the inlet arc region  60 . Similarly, the undervane portion  23  of the vanes traversing the discharge arc region  62  and the seal arc regions  64   a  and  64   b  are supplied with high pressure from the buckets located in the discharge arc region  62 . The pressure, in the form of pressurized fluid, is supplied from the inlet arc region  60  and discharge arc region  62  to the undervane portion  23  of each vane element  18  by way of flow ports machined in the rotor body portion and by providing end plates which have flow channels formed therein.  
         [0045]    Referring to FIGS. 4 and 5, the body portion  19  of rotor  16  includes a plurality of flow ports  84  formed therein. Each flow port  84  is positioned between the plurality of circumferentially spaced apart radial vane slots  17  and provides a path for fluid to flow from the pumping cavity to channels  66   i  and  66   d  ( see FIG. 3) formed in end plate  40 , or in both end plate  40  and  42 . Each flow port  84  is substantially T-shaped and includes a radial conduit  85  and an axial conduit  86 .  
         [0046]    This feature is advantageous because fluid must travel radially inward from the bucket into each flow port  84 , against the centrifugal force created by the rotation, so that the fluid is effectively filtered prior to entering each flow port  84 . Moreover, particulate contained within the fluid in the pumping chamber is forced radially outward by the centrifugal motion, leaving particulate free fluid on the radially inner portion of the bucket.  
         [0047]    Referring now to FIG. 3, arcuate outer channels  66   i  and  66   d  are formed in face  44  of endplate  40  and are in fluid communication with the inlet and discharge arc regions,  60  and  62 , respectively by way of flow ports  84  of rotor member  16 . Low pressure fluid from the inlet arc region  60  is received into arcuate outer channel  66   i  and then flows radially inward through passages  68   a - e  to arcuate inner channel  69   i.  The passages  68   a - e  and the inner channel  69   i  are also formed in face  44  of side plate  40 . Inner channel  69   i  communicates with the undervane portion of each vane element  18  positioned within the inlet arc region  60 .  
         [0048]    In a similar manner, on the discharge side of the pumping chamber, high pressure fluid from within the discharge arc region  62  is received by arcuate outer channel  66   d.  The fluid then flows radially inward through passages  67   a - d  to arcuate inner channel  69   d.  As before, the passages  67   a - d  and the inner channel  69   d  are each machined into face  44  of side plate  40 . Arcuate inner channel  69   d  communicates with the undervane portion of each vane element  18  positioned within the discharge arc region  62  and the sealing arc regions  64   a  and  64   b.  One skilled in the art would readily appreciate that the quantity of channels and passages can be varied depending on the configuration of the pump and the associated operating pressures.  
         [0049]    The communication of pressurized fluid through the above described series of ports and channels to the undervane portion of each vane element functions to balance the forces imparted on the vanes or at least to ensure that a net force directed radially outward is applied thereto.  
         [0050]    As mentioned above, one of the disadvantages associated with vane pump technology is the failure mode. Unlike conventional gear pumps, which will not start up when the pumping elements have experienced a pre-determined amount of wear, traditional vane pumps fail without warning and often catastrophically during pump operation.  
         [0051]    Fuel pump  10  is adapted and configured to change the failure mode normally associated with vane pump technology to one which is substantially similar to that of gear pumps. As illustrated in FIGS. 3 and 4, a series of leak paths  87   a  and  87   b  are formed in ends  92   a  and  92   b  of body portion  19  of rotor member  16 . These leak paths  92   a  and  92   b  allow high pressure which is contained with arcuate outer channel  66   d,  arcuate inner channel  69   d  and passages  67   a - d  to flow into the low pressure inlet arc region  60  when the vane elements  18  have worn such that the undervane portion  23  is positioned radially outward of leak paths  87   a  and  87   b.    
         [0052]    More specifically, in a variable displacement vane pump, maximum vane protrusion from within the corresponding slot occurs when cam member  14  is disposed in the position corresponding to pump start-up, as illustrated in FIG. 1. As depicted, in the pump start-up position, the vane elements  18  located in sealing arc region  64   a  are subjected to the maximum protrusion from within the vane slots  17 . When vane pump  10  is new and not worn, the undervane portion  23  of each vane element  18  prevents fluid from flowing into leak paths  87   a  and  87   b.  However, as the vane tips  21  wear due to their contact with the circumferential surface  24  of the pumping cavity, the radial position of the undervane portion  23  of each vane element  18  with respect to leak paths  87   a  and  87   b  is altered. Eventually, the vane elements  18  wear to the extent that the undervane portion  23  is positioned radially outward of the leak paths  87   a  and  87   b,  and can no longer prevent fuel from leak paths  87   a  and  87   b.  Consequently, the leak paths  87   a  and  87   b  formed in rotor  16  begin to slowly communicate high pressure fuel to the low pressure inlet side of the sealing arc  64   a.    
         [0053]    Referring now to FIG. 6, vane elements  18  of vane pump  10  are shown in a worn condition. As the vane elements  18  wear, it is through the channels or recesses formed in the end plates, that the high pressure communicates to the low pressure side of the pump. As wear continues further, this communication becomes more pronounced and substantial. Eventually, a certain level of leakage through this path is achieved such that the ability of the pump to provide sufficient flow to start the engine becomes diminished and start-up cannot occur. Thus, it will be necessary to remove the pump for overhaul prior to attaining a point where failure due to an overloaded vane is imminent and a major failure can be avoided.  
         [0054]    The failure mode only affects the engine&#39;s ability to start. Higher leakage during operation is not critical to the survival of a mission and therefore there is no danger that the additional leakage will interfere with engine operation. This operational scenario is identical to that of a gear pump.  
         [0055]    The radial position of the leak paths  87   a  and  87   b  are established based on the configuration and size of the pumping components and the material properties of the vane elements. The leak path location is selected so that the above-described failure mode is ensured and catastrophic operational failures are avoided.  
         [0056]    It is envisioned that the porting connections of the pump can be achieved through a variety of methods. Pump configurations can use various cuts in cams, sideplates and rotors to communicate different pressures for different reasons including, but not limited to, bearing lubrication, pressure balancing and the like. The preferred embodiment of the invention utilizes porting cuts in the rotor to provide for a controlled failure mode thus providing the vane pump with operational reliability similar to that of a gear pump.  
         [0057]    While the invention has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the invention without departing from the spirit or scope of the invention as defined by the appended claims.