Counter-rotating rotor system with stationary standpipe

The subject matter disclosed herein relates to the art of rotary wing aircraft and, more specifically, to coaxial multi-rotor systems for rotary wing aircraft.

In typical rotary winged aircraft, for example, helicopters with dual coaxial rotor systems, rotary power is transmitted from an engine through a gearbox into the rotor system. The gearbox transfers power to a lower rotor shaft to drive a lower rotor assembly and to an upper rotor shaft coaxial with the lower rotor shaft to drive the upper rotor assembly. The systems typically include several sets of bearings between the upper rotor shaft and lower rotor shaft to transfer loads between the shafts and to the housings. The bearings and controls for the upper rotor assembly drive an increased diameter for the upper rotor shaft, and thus the lower rotor shaft, which increases drag during operation. As such, many coaxial rotor systems include an aerodynamic fairing positioned between the upper rotor assembly and the lower rotor assembly. Typical systems attach to the upper and lower rotor shafts and include a significant derotation mechanism to prevent the fairing from rotating with respect to the airframe, and to keep the fairing oriented in a selected direction.

In one embodiment, a coaxial, dual rotor system connected to a gearbox includes a first rotor assembly is located at a rotor axis and which imparts a first axial load and a first moment and a first rotor shaft operably connected to the first rotor assembly at the rotor axis to drive rotation of the first rotor assembly about the rotor axis. A first bearing assembly connects the gearbox to the first rotor shaft and transfers the first axial load from the first rotor shaft to the gearbox. A second rotor assembly is located at the rotor axis and imparts a second axial load and a second moment. A second rotor shaft is operably connected to the second rotor assembly at the rotor axis to drive rotation of the second rotor assembly about the rotor axis, the second rotor shaft coaxial with and radially offset from the first rotor shaft. A second bearing assembly connects the gearbox to the second rotor shaft and transfers the second axial load from the second rotor shaft to the gearbox. A nonrotating standpipe is located at the rotor axis radially between the first rotor shaft and the second rotor shaft. An intershaft bearing assembly is located at the standpipe and transfers the first and second moments from the first rotor assembly and the second rotor assembly to the standpipe using the first and second bearing assemblies.

In another embodiment, a dual coaxial rotor rotorcraft includes an airframe and a drive system including a gearbox located at the airframe. A dual coaxial rotor system is operably connected to the drive system. The rotor system includes a first rotor assembly is located at a rotor axis and which imparts a first axial load and a first moment and a first rotor shaft operably connected to the first rotor assembly at the rotor axis to drive rotation of the first rotor assembly about the rotor axis. A first bearing assembly connects the gearbox to the first rotor shaft and transfers the first axial load from the first rotor shaft to the gearbox. A second rotor assembly is located at the rotor axis and imparts a second axial load and a second moment. A second rotor shaft is operably connected to the second rotor assembly at the rotor axis to drive rotation of the second rotor assembly about the rotor axis, the second rotor shaft coaxial with and radially offset from the first rotor shaft. A second bearing assembly connects the gearbox to the second rotor shaft and transfers the second axial load from the second rotor shaft to the gearbox. A nonrotating standpipe is located at the rotor axis radially between the first rotor shaft and the second rotor shaft. An intershaft bearing assembly is located at the standpipe and transfers the first and second moments from the first rotor assembly and the second rotor assembly to the standpipe using the first and second bearing assemblies. These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.

The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a schematic view of an embodiment of a rotary wing aircraft;

FIG. 2 is a cross-sectional view of an embodiment of a dual coaxial rotor system and gearbox; and

FIG. 3 is a cross-sectional view of another embodiment of a dual coaxial rotor system and gearbox.

The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.

Shown in FIG. 1 is schematic view of an embodiment of a rotary wing aircraft, in this embodiment a helicopter 10 . The helicopter 10 includes an airframe 12 with an extending tail 14 . A dual, counter rotating coaxial main rotor assembly 18 is located at the airframe 12 and rotates about a main rotor axis 20 . The main rotor assembly 18 is driven by a power source, for example, an engine 24 via a gearbox 26 . The main rotor assembly 18 includes an upper rotor assembly 28 driven in a first direction 30 about the main rotor axis 20 , and a lower rotor assembly 32 driven in a second direction 34 about the main rotor axis 20 , opposite to the first direction 30 . While, in FIG. 1 , the first direction 30 is illustrated as counter-clockwise and the second direction 34 is illustrated as clockwise (when looking downward), it is to be appreciated that in some embodiments the directions of rotation of the upper rotor assembly 28 and lower rotor assembly 32 may be reversed. Each of the upper rotor assembly 28 and the lower rotor assembly 32 include a plurality of rotor blades 36 secured to a rotor hub 38 . In some embodiments, the helicopter 10 further includes a translational thrust system 40 located at the extending tail 14 to provide translational thrust for the helicopter 10 . The translational thrust system 40 includes a propeller rotor 42 connected to and driven by the engine 24 via the gearbox 26 . While shown in the context of a pusher-prop configuration, it is understood that the propeller rotor 42 could also be more conventional puller prop or could be variably facing so as to provide yaw control in addition to or instead of translational thrust.

Referring to FIG. 2 , the upper rotor assembly 28 is driven by an upper rotor shaft 44 axially supported at the gearbox 26 by an upper rotor bearing 46 . At the gearbox 26 , a lower bull gear 48 mated to the upper rotor shaft 44 is driven via a lower output pinion 50 thus driving rotation of the upper rotor shaft 44 and the upper rotor assembly 28 . Similarly, lower rotor assembly 32 is connected to and driven by a lower rotor shaft 52 , which is coaxial with the upper rotor shaft 44 and located radially outboard of the upper rotor shaft 44 . The lower rotor shaft 52 is axially supported at the gearbox 26 by a lower rotor bearing 54 set, and is connected to an upper bull gear 56 driven by an upper output pinion 58 . While the gearbox 26 in the present embodiment includes bull gears 48 and 56 , it is merely exemplary. Other gear types, such as spiral bevel gears, may be utilized. A stationary standpipe 60 is coaxial with the upper rotor shaft 44 and the lower rotor shaft 52 , and is located radially between the upper rotor shaft 44 and the lower rotor shaft 52 . The standpipe 60 is fixed to a non-rotating part of the gearbox 26 , for example, a gearbox housing 62 , via, in some embodiments a spline connection 64 . The standpipe 60 extends along the main rotor axis 20 , terminating between the upper rotor assembly 28 and the lower rotor assembly 32 .

The upper rotor shaft 44 transfers lift loads to the gearbox 26 via the upper rotor bearing 46 at a base 66 of the upper rotor shaft 44 . Upper rotor assembly 28 moment loads are coupled at the upper rotor bearing 46 and at an intershaft shear bearing 68 located between the upper rotor shaft 44 and the standpipe 60 at an upper end of the lower rotor shaft 52 to transfer loads from the upper rotor shaft into the standpipe. The lower rotor shaft 44 transfers lift loads into the gearbox 26 via lower rotor bearing 54 located at a base of the lower rotor shaft 44 . Lower rotor assembly 32 moment loads are coupled between the lower shaft bearings 80 and 82 at the lower rotor shaft 52 .

Referring now to FIG. 3 , the standpipe 60 provides a nonrotating structure at which to mount an aerodynamic fairing 74 between the upper rotor assembly 28 and the lower rotor assembly 32 . To facilitate installation of the fairing 74 , the standpipe 60 may include, for example, an arrangement of studs or bolts 76 , which align with openings (not shown) in the fairing 74 and are used to secure the fairing 74 to the standpipe 60 . While shown as empty, it is understood that the fairing 74 could be solid, or can house electronics or other boxes. While in the embodiment shown, a fairing 74 is installed on the standpipe 60 , it is to be appreciated that the standpipe 60 may be utilized to locate and secure various nonrotating elements, such as RADAR domes, slip rings, LIDAR equipment, or other electronic or mechanical equipment.

While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. For instance, aspects can be used with propeller assemblies, turbines, and/or fans. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.