Patent Description:
A turbine engine, for example a gas turbine engine, is engaged in regular operation to an air starter. Air starters are typically removably coupled to the engine through a gearbox or other transmission assembly when it is desired to start the turbine engine. The transmission transfers power from the air starter to the engine to assist in starting the engine. The internal components of both the turbine engine and the air starter spin together such that the air starter can be used to start the engine.

Air starters for turbine engines run for a limited amount of time. If the turbine engine does not start within the limited run time of the air starter, the air starter must go through a cool-down process before a second attempt at starting the turbine engine can take place. The amount of time an air starter can run is often controlled by the temperature of internal rotating components, such as one or more bearings in a bearing assembly.

<CIT> relates to a planetary gear system and air turbine starter. The air turbine starter includes a housing defining an inlet, an outlet, and a flow path extending between the inlet and the outlet for communicating a flow of gas there through. A turbine member is journaled within the housing and disposed within the flow path for rotatably extracting mechanical power from the flow of gas and having a turbine output shaft. <CIT> relates to pneumatic starters.

<CIT> discloses a turbine rotor bearing with cooling a lubricating means. A tubular bearing support has a central opening through which a shaft extends and circulation passages extend inwardly from the ends of the support and communicate with the central opening. The tubular bearing support further has cooling passages therein in heat exchange relation with the circulation passages.

In one aspect, the disclosure relates to an air starter according to claim <NUM> that includes a housing defining an interior having a primary inlet and a primary outlet to define a primary air flow path from the primary inlet to the primary outlet, a turbine located within the interior, an output shaft coupled to the turbine, at least one bearing located in the housing and rotationally supporting the output shaft, and a cooling passage adjacent the at least one bearing and having a cooling inlet and a cooling outlet, to define cooling air flow path from the cooling inlet to the cooling outlet, with the cooling inlet fluidly coupled to the primary air flow path whereby a portion of air in the primary air flow path passes through the cooling passage and cools the bearing.

In another aspect, the disclosure relates to an air starter according to claim <NUM> that includes a housing having a peripheral wall defining an interior, the housing having a primary inlet and a primary outlet to define a primary air flow path from the primary inlet to the primary outlet, with the primary outlet comprising a plurality of openings circumferentially arranged in the peripheral wall, a retention member located within the interior and mounted to the housing in axial alignment with the primary outlet, the retention member having an axial face forming a portion of the primary air flow path and having a bearing housing on a downstream side of the axial face, at least two axially-spaced bearings mounted within the bearing housing, an output shaft rotationally supported in the at least two axially-spaced bearings and having a portion upstream of the retention member, a turbine mounted to the portion of the output shaft upstream of the retention member, and a cooling passage extending through the retention member along the bearing housing and having a cooling inlet on the axial face of the retention member and a cooling outlet separate from the primary outlet.

In yet another unclaimed aspect, the disclosure relates to a method of cooling a bearing assembly in an air starter having a primary air flow path flowing over a turbine rotationally supported by a bearing assembly, the method comprising diverting a portion of air from the primary air flow path to flow over the bearing assembly.

Aspects of the disclosure described herein are directed to a turbine engine with an air starter that includes a retaining member with at least one cooling passage for cooling at least one bearing assembly of the air starter. For purposes of illustration, the present disclosure will be described with respect to an air starter for an aircraft turbine engine. For example, the disclosure can have applicability in other vehicles or engines, and can be used to provide benefits in industrial, commercial, and residential applications. Further non-limiting examples of other vehicles or engines to which the disclosure can relate can include boats, cars, or other aquatic or land vehicles. Industrial, commercial, or residential applications of the disclosure can include, but are not limited to, marine power plants, wind turbines, small power plants, or helicopters.

As used herein, the term "upstream" refers to a direction that is opposite the fluid flow direction, and the term "downstream" refers to a direction that is in the same direction as the fluid flow. The term "fore" or "forward" means in front of something and "aft" or "rearward" means behind something. For example, when used in terms of fluid flow, fore/forward can mean upstream and aft/rearward can mean downstream.

Additionally, as used herein, the terms "radial" or "radially" refer to a direction away from a common center. For example, in the overall context of a turbine engine, radial refers to a direction along a ray extending between a center longitudinal axis of the engine and an outer engine circumference. Furthermore, as used herein, the term "set" or a "set" of elements can be any number of elements, including only one.

All directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, aft, etc.) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of aspects of the disclosure described herein. Connection references (e.g., attached, coupled, secured, fastened, connected, and joined) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to one another. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto can vary.

Referring to <FIG>, a starter motor or air starter <NUM> is coupled to an accessory gear box (AGB) <NUM>, also known as a transmission housing, and together are schematically illustrated as being mounted to a turbine engine <NUM> such as a gas turbine engine. The turbine engine <NUM> comprises an air intake with a fan <NUM> that supplies air to a high pressure compression region <NUM>. The air intake with a fan <NUM> and the high pressure compression region collectively are known as the 'cold section' of the turbine engine <NUM> upstream of the combustion. The high pressure compression region <NUM> provides a combustion chamber <NUM> with high pressure air. In the combustion chamber, the high pressure air is mixed with fuel and combusted. The hot and pressurized combusted gas passes through a high pressure turbine region <NUM> and a low pressure turbine region <NUM> before exhausting from the turbine engine <NUM>. As the pressurized gases pass through the high pressure turbine (not shown) of the high pressure turbine region <NUM> and the low pressure turbine (not shown) of the low pressure turbine region <NUM>, the turbines extract rotational energy from the flow of the gases passing through the turbine engine <NUM>. The high pressure turbine of the high pressure turbine region <NUM> can be coupled to the compression mechanism (not shown) of the high pressure compression region <NUM> by way of a shaft to power the compression mechanism. The low pressure turbine can be coupled to the fan <NUM> of the air intake by way of the shaft to power the fan <NUM>.

The turbine engine can be a turbofan engine, such as a General Electric GEnx or CF6 series engine, commonly used in modern commercial and military aviation or it could be a variety of other known turbine engines such as a turboprop or turboshaft.

The AGB <NUM> is coupled to the turbine engine <NUM> at either the high pressure or low pressure turbine region <NUM>, <NUM> by way of a mechanical power take-off <NUM>. The mechanical power take-off <NUM> contains multiple gears and means for mechanical coupling of the AGB <NUM> to the turbine engine <NUM>. Under normal operating conditions, the mechanical power take-off <NUM> translates power from the turbine engine <NUM> to the AGB <NUM> to power accessories of the aircraft for example but not limited to fuel pumps, electrical systems, and cabin environment controls. The air starter <NUM> can be mounted on the outside of either the air intake region containing the fan <NUM> or on the core near the high pressure compression region <NUM>. Optionally, an air intake conduit <NUM> can couple to the air starter <NUM>. The air intake conduit <NUM> can supply the air starter <NUM> with pressurized air.

Referring now to <FIG>, an example of an air starter <NUM> is shown. Generally, the air starter <NUM> includes a housing <NUM> defining an interior <NUM> having a primary inlet <NUM> and a primary outlet <NUM>. A primary air flow path <NUM>, illustrated schematically with an arrow, extends between the primary inlet <NUM> and the primary outlet <NUM> for communicating a flow of fluid, including, but not limited to gas, compressed air, or the like, there through. The primary outlet <NUM> can include a plurality of circumferentially arranged openings <NUM> in a peripheral wall <NUM> of the housing <NUM>. In this configuration, the primary inlet <NUM> is an axial inlet and the primary outlet <NUM> is a radial or circumferential outlet alone the periphery of the housing <NUM>.

The housing <NUM> can be made up of two or more parts that are combined together or can be integrally formed as a single piece. In the depicted aspects of the disclosure, the housing <NUM> of the air starter <NUM> generally defines, in an axial series arrangement, an inlet assembly <NUM>, a turbine section <NUM>, a gear box <NUM>, and a drive section <NUM>. The air starter <NUM> can be formed by any materials and methods, including, but not limited to, additive manufacturing or die-casting of high strength and lightweight metals such as aluminum, stainless steel, iron, or titanium. The housing <NUM> and the gear box <NUM> can be formed with a thickness sufficient to provide adequate mechanical rigidity without adding unnecessary weight to the air starter <NUM> and, therefore, the aircraft.

<FIG> is a schematic cross section of the air starter <NUM> of <FIG> along the sectional line III-III further illustrating the inlet assembly <NUM>, the turbine section <NUM>, and the gear box <NUM> in greater detail. The inlet assembly <NUM> can include stationary portions <NUM> to guide air in the primary air flow path <NUM> and define at least a portion of a primary air flow path <NUM> from the primary inlet <NUM> to the turbine section <NUM>. In one non-limiting example fluid or air is supplied to the primary air flow path <NUM> from either a ground-operating air cart, an auxiliary power unit, or a cross-bleed start from an engine already operating.

The turbine section <NUM> of the air starter <NUM> can include, but is not limited to, a turbine <NUM>, a retention member <NUM>, and the primary outlet <NUM>. The turbine <NUM> can rotate about a centerline <NUM> of the air starter <NUM>. Alternatively, the turbine <NUM> can rotate about any axis relative to the air starter <NUM>. A drive shaft or output shaft <NUM> couples to the turbine <NUM> allowing for the transfer of energy from air in the primary air flow path <NUM> to mechanical power. The output shaft <NUM> can extend through at least a portion of the inlet assembly <NUM>, the turbine section <NUM>, or the gear box <NUM>. By way of non-limiting example, the output shaft <NUM> can couple the turbine <NUM> to one or more gears or clutch assemblies such as a gear train <NUM> in the gear box <NUM>.

The retention member <NUM> located in the interior <NUM> of the housing <NUM> circumscribes at least a portion of the output shaft <NUM>. The retention member <NUM> can include or define a receiving portion or pocket <NUM>. A bearing assembly <NUM> can be received in the pocket <NUM>, located radially between at least a portion of the retention member <NUM> and the output shaft <NUM>. The bearing assembly <NUM> rotationally supports the output shaft <NUM>. The bearing assembly <NUM> can include at least a bearing housing <NUM> and at least one bearing <NUM>. As illustrated by way of non-limiting example, the bearing housing <NUM> includes two axially spaced bearings <NUM>. The bearings <NUM> can be circumscribed by the bearing housing <NUM>, retained by the retention member <NUM>, and mounted to the output shaft <NUM>.

An upstream axial face <NUM> of the retention member <NUM> can define at least a part of the primary air flow path <NUM> that directs air from the primary inlet <NUM> or the inlet assembly <NUM> to the primary outlet <NUM>. By way of non-limiting example, at least a portion of the axial face <NUM> of the retention member <NUM> is a deflector <NUM> axially aligned with the circumferentially arranged openings of the primary outlet <NUM>.

The axial face <NUM> of the retention member <NUM> can include at least one opening <NUM> that defines at least one cooling inlet <NUM>. It is contemplated that more than one opening <NUM> or cooling inlet <NUM> can be located circumferentially in the axial face <NUM> retention member <NUM> about the output shaft <NUM>. The cooling inlet <NUM> allows for a portion of air from the primary air flow path <NUM> to enter a cooling passage <NUM> at least partially housed within the retention member <NUM>. A peripheral edge <NUM> of the retention member <NUM> includes at least one opening <NUM> that defines at least one cooling outlet <NUM>. A cooling air flow path <NUM> can be defined by the cooling inlet <NUM>, the cooling passage <NUM>, and the cooling outlet <NUM>. The cooling outlet <NUM> can be at an axial location downstream of the primary outlet <NUM>. That is, the cooling outlet <NUM> is separate from the primary outlet <NUM> and can have, by way of non-limiting example, an axial distance <NUM> between the cooling outlet <NUM> and the primary outlet <NUM>.

<FIG> further illustrates the cooling air flow path <NUM> that extends from the least one cooling inlet <NUM> defined by the axial face <NUM> to the at least one cooling outlet <NUM> via the cooling passage <NUM>. By way of non-limiting example, the cooling passage <NUM> can be a labyrinth passage <NUM> in the retention member <NUM> that includes a first, second, and third portion <NUM>, <NUM>, <NUM>. It is contemplated that the cooling passage <NUM> can include at least one turn.

The first portion <NUM> can extend from the cooling inlet <NUM> to a lower portion <NUM> portion of the bearing housing <NUM> that is proximate the bearings <NUM>. It is contemplated that the cooling passage <NUM> or labyrinth passage <NUM> can include an extended corner or cavity. As illustrated in a non-limiting example, a first extended corner or first cavity <NUM> can be located in the first portion <NUM> of the cooling passage <NUM> or labyrinth passage <NUM>. It is contemplated that at least part of the first portion <NUM> can be linear or curvilinear.

The second portion <NUM> of the cooling passage <NUM> or labyrinth passage <NUM> extends generally parallel to the lower portion <NUM> bearing housing <NUM>. It is contemplated that a first turn can be defined by at least part of the first and second portions <NUM>, <NUM>. The first turn can include a first angle <NUM> measured between the first and second portions <NUM>, <NUM> can be between or include <NUM> degrees to <NUM> degrees. The first angle <NUM> can be measured from a first centerline <NUM> of the first portion <NUM> to a second centerline <NUM> of the second portion <NUM>.

Downstream of the axial face <NUM> of the retention member <NUM>, the bearing housing <NUM> can define at least a portion of the cooling passage <NUM> or labyrinth passage <NUM>. Heat from the bearing housing <NUM> can be transferred to air in the cooling air flow path <NUM>. As illustrated by way of non-limiting example, the second portion <NUM> can include an impingement zone, extended corner, or cavity illustrated as a second cavity <NUM> It is contemplated that at least part of the second portion <NUM> can be linear or curvilinear.

The third portion <NUM> can extend from the bearing housing <NUM> to the cooling outlet <NUM>. At least part of the third portion <NUM> can be linear or curvilinear. It is contemplated that a second turn can be defined by at least part of the second and third portions <NUM>, <NUM>. The second turn can include a second angle <NUM> between the second centerline <NUM> of the second portion <NUM> and a third centerline <NUM> of the third portion <NUM> can be <NUM> degrees. It is further contemplated that the second angle <NUM> can be between or include <NUM> degrees to <NUM> degrees. The third portion <NUM> can be proximal to a portion of the gear box <NUM> that contains cooling or lubricating fluids such as oil.

Optionally, at least one surface geometry <NUM> can be located along portion of the cooling air flow path <NUM> or labyrinth passage <NUM>. The surface geometry <NUM> is illustrated in dotted lines and can include, in any combination or singularity, forward facing steps, pins, turbulators, aft facing steps, bumps, ridges, or dimples. The inclusion of the surface geometry <NUM> in the cooling air flow path <NUM> can decrease or increase the radius of one or more portions of the cooling passage <NUM> or labyrinth passage <NUM>. It is contemplated that one or more surface geometries <NUM> can be located in one or more of the first, second, or third portions <NUM>, <NUM>, and <NUM> of the cooling passage <NUM> or labyrinth passage <NUM>. It is further contemplated that the one or more surface geometries <NUM> can also be used to change the velocity of at least a portion of the fluid or air in order to obtain a desired speed, direction, or momentum.

While illustrated as exhausting outside of the air starter <NUM>, it is contemplated that the cooling outlet <NUM> can deliver air from the cooling passage <NUM> to any location interior or exterior of the air starter <NUM>. It is further contemplated that air for the purpose of cooling can be supplied to the cooling inlet <NUM> of the cooling air flow path <NUM> from any location interior or exterior of the air starter <NUM>.

<FIG> provides a perspective view of the retention member <NUM>. The axial face <NUM> of the retention member <NUM> illustrates the at least one opening <NUM> as multiple openings. The multiple openings can define multiple cooling inlets <NUM>. While each cooling air flow path <NUM> is illustrated as having one cooling inlet <NUM>, it is contemplated that any number of cooling inlets <NUM> can couple to each cooling passage <NUM> of the cooling air flow path <NUM>.

The peripheral edge <NUM> of the retention member <NUM> illustrates the at least one opening <NUM> as multiple openings. The multiple openings can define multiple cooling outlets <NUM>. While each cooling passage <NUM> is illustrated as having two cooling outlets <NUM>, it is contemplated that a plurality of openings can define any number of cooling outlets <NUM> for each cooling air flow path <NUM>.

While illustrated, by way of non-limiting example as an oval, the cooling inlets <NUM> can be any shape or inclination. Similarly, the cooling outlets <NUM> are illustrated as circular. It is contemplated that the shape of the cooling outlet <NUM> can be any known shape.

Aspects of the present disclosure can be used in a method of cooling the bearing assembly <NUM> in the air started <NUM> that includes the primary air flow path <NUM> that flows over the turbine <NUM> rotationally supported by the bearing assembly <NUM>. The method can include cooling the bearing assembly <NUM> by diverting a portion of air from the primary air flow path <NUM> to flow over the bearing assembly <NUM>. The diverted portion of air is emitted from the air starter <NUM> at the cooling outlet <NUM> separate from the primary outlet <NUM>.

In operation, a fluid, for example air, is supplied to the air starter <NUM>. The air enters the primary air flow path <NUM> through the primary inlet <NUM>. The energy from the air is transformed to mechanical energy by the turbine <NUM> which rotates in response to the air flow through the turbine <NUM>. The turbine <NUM> is coupled to the output shaft <NUM>, such that the rotational energy from the turbine <NUM> can be transferred to the gear box <NUM> via the output shaft <NUM>. The at least one bearing <NUM> housed in the bearing housing <NUM> rotatably supports the output shaft <NUM>. The bearing housing <NUM> can be formed in or supported by the retention member <NUM>.

Once past the turbine <NUM>, the air is cooler and less compressed. The air from the turbine <NUM> continues through the primary air flow path towards the primary output <NUM>. The retention member <NUM> forms at least a part of the primary air flow path. The axial face <NUM> of the retention member <NUM> includes the at least one cooling inlet <NUM> and the deflector <NUM>. The deflector <NUM> directs a portion of the air flow in the primary air flow path <NUM> to the primary outlet <NUM>.

The cooling inlet <NUM> allows the retention member <NUM> to bleed or divert a portion of the air from the primary air flow path <NUM> through the cooling air flow path <NUM>. The air enters the cooling air flow path <NUM> via the cooling inlet <NUM> and continues through the cooling passage <NUM> or labyrinth passage <NUM>. At least a portion of the cooling passage <NUM> or labyrinth passage <NUM> is the proximate the bearing housing <NUM> to cool the at least one bearing <NUM>. It is also contemplated that the bearing housing <NUM> forms a portion of the cooling passage <NUM> or labyrinth passage <NUM>. Heat from the bearings <NUM> can be transferred to the bearing housing <NUM> and to the air in the cooling passage <NUM> or labyrinth passage <NUM>. That is, a portion of the air in the primary air flow path <NUM> passes through the cooling passage <NUM> and cools the bearing <NUM>.

Optionally, the air flow through the cooling passage <NUM> or labyrinth passage <NUM> can be directed to a portion of the cooling passage <NUM> or labyrinth passage <NUM> adjacent to or proximal to the gear box <NUM>. The air in the cooling passage <NUM> or labyrinth passage <NUM> can absorb heat from portions of the gear box <NUM>. The gear box portions <NUM> can include cooling or lubricating fluids such as, but not limited to, oil.

Benefits associated with aspects of the disclosure herein include cooling of the bearings. The temperature of the bearings is often one of the limiting factors in determining the length of time the air starter can operate before requiring cool down time. Aspects of the present invention reduce the temperature of the bearings during motoring, which increases the amount of time the air starter can operate. Longer operation of the air starter allows for multiple attempts at firing the turbine engine from the air starter before requiring a cool down period for the air starter.

Additional benefits include a longer part life due to increased cooling of the parts. Aspects of the present invention provide a reduced thermal load on the air starter.

Yet another benefit of the present disclosure is a reduction in lubricant or oil temperatures while the starter is in operation. Reduced lubricant or oil temperatures can further improve the part life as well as the life of the lubricant or oil.

Claim 1:
An air starter (<NUM>) comprising:
a housing (<NUM>) defining, in an axial series arrangement, an inlet assembly (<NUM>), a turbine section (<NUM>), a gear box (<NUM>), and a drive section (<NUM>), the housing defining an interior (<NUM>) having a primary inlet (<NUM>) located in the inlet assembly (<NUM>) and a primary outlet (<NUM>) located in the turbine section (<NUM>) to define a primary air flow path (<NUM>) from the primary inlet (<NUM>) to the primary outlet (<NUM>);
a turbine (<NUM>) located in the turbine section (<NUM>) within the interior (<NUM>);
an output shaft (<NUM>) coupled to the turbine (<NUM>);
at least one bearing (<NUM>) located in the housing (<NUM>) and rotationally supporting the output shaft (<NUM>);
the air starter being characterized in that it further comprises
a cooling passage (<NUM>) located in the turbine section (<NUM>) adjacent the at least one bearing (<NUM>) and having a cooling inlet (<NUM>) and a cooling outlet (<NUM>), to define cooling air flow path (<NUM>) from the cooling inlet (<NUM>) to the cooling outlet (<NUM>), with the cooling inlet (<NUM>) fluidly coupled to the primary air flow path (<NUM>) whereby a portion of air in the primary air flow path (<NUM>) passes through the cooling passage (<NUM>) and cools the least one bearing (<NUM>).