US 20090199S67AI IMO IW co») United States c2) Patent Application Publication (0) Pub. No.: US 2009/0199567 Al Gockel et al. (43) Pub, Date: Aug. 13, 2009 (34) DECOUPLER DEVICES TO PREVENT Publication Classification BACKDRIVE IN AIR TURBINE STARTERS, 5 2 (2006.01) 8) Inventors: Gre Mem AZ) foe o1) yma, Chandler, AZ. ( ae Arun Kumar, Chandler, AZ (US) ~ ee oe Doug Smith, Phoenix, AZ (US): ABSTRACT oe Silk, Chandler, AZ.( Ho, Tempe, AZ (US) ing, and a flow path communicating a flow of gas there . trough: a turbine member, clutch: anda decouple device Conrespondence Address at least paially housed within the output member of the HONEYWELL INTERNATIONAL INC. clutch. The decoupler device includes a frst shaft portion PATENT SERVICES coupled to and rotating with te outpot member and a second 101 COLUMBIA ROAD, P.O BOX 2248 shal portion coupled to and rotating with te engine. The fist MORRISTOWN, NJ 07962-2245 (US) and second shaft portions are axially aligned and configured . : 36 a 4 32 18 6 S 7 ja aoe Ae 2 | oe : lores | 24° 26 95, s ca :Aug. 13,2009 Sheet 1 of 5 US 2009/0199567 Al FIG.1uoneanand woneonddy aye $JOZI99YS 6007 ‘ET “Bay TY £956610/6007 S11.Patent Application Publication Aug. 13, 2009 Sheet 3 of 5 US 2009/0199567 Al FIG. 3a © 6 Aug. 13, 2009 Sheet 4 of 5 US 2009/0199567 Al 366 351 352 FIG, 4 } 354 338 3507Patent Application Publication Aug. 13, 2009 Sheet 5 of 5 ~ | Zak i KS S ON SE . | yiUS 2009/0199567 Al DECOUPLER DEVICES TO PREVENT BACKDRIVE IN AIR TURBINE STARTERS ‘TECHNICAL FIELD [0001] ‘The present invention generally relates to docoupler ‘devices of at turbine starters capable of driving in one direc tion only, and decoupling in response toa specific torque load in the opposite direction. BACKGROUND 10002] Aicwrbine staers are known inthe viaton field, and are commonly set start propulsion turbine engines oF modern sirerafl. A starter typically inchodes clutch that ‘overruns when the turbine engine achieves a certain operating spec. Sich oveeraming can occur continuously daring ‘operation ofthe turbine engine. In some instance, if prob Temi wit the cute occur, te clutch may transmit reverse tongue and hackdeve the air turbine starter To prevent uade- sirable backériving of the starter by the turbine engine, a ddecoupler device is conventionally provided in the power train between the tater and turbine engine [0003] Unfortunately, 2 conventional decoupler devive may suffer from one or more shortcomings. The conventional «decouple device may’ be ovely large oe comple in its om struction, ean provide a possible source of malfunction oF breakcown, may undesirably reset sutomatically to torque transmitting condition afer itis tripped by a everse torque, andor may require extensive ine consuming disessemby 0 reset afer ben tepped bya reverse torque incident. More- ‘over, portions of the dvoupler device may wear and overheat the starter during a decoupled condition. Overheating ofthe starter may esl inthe decouper device failing to prevent backdriving of te tater 10008) Accocdingly. i is desirable 10 provide improved decoupler doves for use with air turbine starters. Adition- ally. it is desirable provide deoupler devices that redoce ‘wear between the decouper device and ater portions ofthe Starter. Furthermore, oer desirable features and character ists ofthe present invention wll come apparent rom the subsequent detailed description of the invention and the appended claims, faken in conjunction withthe aesompany~ ing drawings and this Background of the invention BRIEF SUMMARY [0005] In accordance with an exemplary embodiment, an sir turbine starter is proved for stating an engine. The Starter includes a housing defining an inlet, an outlet, and a flow path extending between te inlet andthe outlet for com- municating a flow of gas therethrough; a turbine member Jjoumaled within the housing and disposed within the Dow path for rotatably extracting mechanical power from the gas flow, a gear rain drivingly coupled withthe turbine member, clutch coupled withthe gear train and including an output ‘member with an inner surface; anda decoupler devieeat least Partially housed within the output member of the clutch, The ‘decoupler device includes a first shaft portion coupled to and rotating with the outpat member and a second shaft portion ‘coupled to and rotating with the engine. Each ofthe frst and second portions has outer surfaces. The first and second shaft portions are axially aligned and configured 1 engage each ‘another for rotation ina first direction aad to separate fas ‘eachother in a second direction to docouple the output mem- bercf the clutch rom the engine. The starter further includes ‘Aug, 13, 2009 beating between the inner surface ofthe output member and the second shalt for reducing friction between the second shaftportionane the inne surface ofthe output memberwhen the fist and second shaft portions are decoupled, [0006] Ingccordance wth another exemplary embodiment, adecouplerdeviceis provided for decoupling an output mem berofa tater fom an engine. The decoupler device includes firs shaft portion configured o be coupled to and rotate with the output member, a second shaft portion configured to be coupled to and rotate with the engine, the first and second shaft portions being axially aligned and configured to engage each another for rotation ina first direction and to separate from each ober in a second direction wo decouple the output ‘member from the engine; anda bearing arangedl between the ‘output member and the second shaft portion for reducing fiction between the second shaft portion and the output member whea the first and second shall portions are decoupled [0007] In accordance with yet another exemplary embodi- ‘met, an air turbine starters provided for stating an engine. ‘Thestarterincludesa housing defining an inlet, an outlet, and a flow path extending between the inlet and the outlet for ‘communicatinga flow of gas therethrough; turbine member journaled within the housing and disposed within the flow path for rotatably extracting mechanical power from the gas flow; a pear train divingly coupled wih the turbine member, a clutch coupled with the gear train and including an output riember having a inner sufice: and a deeoupler deve at Teast partially housed within the output member of the clutch, “The decoupler device includes fist shaft portion fixed tothe output member and a second shaft portion coupled to the engine, with each ofthe first and second portions having an ‘outer surface. The fist and second shaft portions are axially aligned and configured to engage each another for rotation in ‘frst direction and 1 separate from each other in a second iretion to decouple the output member ofthe clutch from the engine. The starter further includes a bushing positioned between the cuter surface of the second shat portion and the Jner surface of the output member ofthe elute or reducing fetion between the second shaft portion andthe inne sue- face o the output member and to restrict dynamic movement ofthe second shaft portion when the first and second shaft portions are decouple. BRIEF DESCRIPTION OF THE DRAWINGS [0008] The present invention will heeinalier be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and {0009} FIG. 1 is a cross-sectional view of an air turbine starter tat ines a decouple device in accordance with an exemplary embodiment; [0010] FG. 2isanenlaned, partial cross-sectional view of the decoupler device of FIG. 1 [011] FG. isan enlaged, partial cross-sectional view of ‘starter with a decoupler device in seeordance with an alter- nate embodiment; [0012] FG. 4s an enlarged, partial eross-setional view of ‘starter with a decoupler device in aeordance with another tltemate embodiment and [0013] FG. Sisanenlaned, partial cross-sectional view of 4 starter with a decoupler device in accordance with yet ‘nother altemate embodiment, DETAILED DESCRIPTION [0014] The following detsiled description is merely exem play in nature and isnot intended to ist the invention or theUS 2009/0199567 Al ‘pplication anduses ofthe invention. Furthermore, there is no imtention tobe bouna by any theory presented in the reved- ing background or the following detailed deseription. [0015] Broadly, exemplary embodiments described herein provide decoupler devieos in starters forengines, typically for sirerall. The decoupler devices function to decouple the starter from the engine during a failure event, Particular ‘exemplary embodiments provide a bearing structure that reduces wear between the decoupler device and other por tions of the starter. The bearing structures ean include, for ‘example, wear coatings, bushings, ball bearings, and roller bearings. 10016] FIG. 1 depicts a cross-sectional view of an exem= lary aie urbine starter 10, The air trbne starter 10 includes 8 housing 12 defining an inlet 16 and an outlet 14. The housing 12 further defines flow path 18 extending between the inlet 16and the outlet 14. Ansxial low turbine member 20 is rotatably journaled by the housing 12 the low path 18 for ‘extracting mechanical energy froma low of pressurized fuid ‘conducted between the inlet 16 and the outlet 14 via the low path 18, The turbine member 20 coupled toa rotatable shaft member 2 journaled by bearings 24 carried by the housing 12. Agear member 26s coupled tothe shalt member 22 and ‘engages a speed-reducing gear train 28. The gear train 28 is, ‘coupled to aclutch 36, which includes an output member 38 ‘The clutch 36 can be a spr clutch of the innerrace-over- running type o a pawl aad ratchet clutch, [0017] The outpur member 38 is coupled to a decoupler ‘device 88, which is then coupled to a combustion turbine ‘engine (not shown) such that energy extracted by the turbine rember 20 can be used to stat the engin, As described in further detail below, the decoupler device 88 functions 10 decouple the air turbine starter 10 from the engine (not shown) during a failure condition. The decouple device $8 drivingly connects with output member 38 via respective ier-engaging male and female spline surfaces, generally indicated at 60. The decouplee device 58 also defines a male spline surface 6 by which the air turbine starter 10 couples in driving relation with o combustion turbine engine (not shown, 10018] Viewing now FIG. 2 in conjunction with FIG. 1, the decoupler device 88 includes fist axial shaft portion 64 und ‘anadjacen, second axial shal portion 66. The first axial shat Portion 64 defines the male spine surface 6 that couples with ‘output member 38, while the second shaft portion 66 defines, spline surface 62 that couples with the engine. The shaft portions 64, 66 cooperatively define a stepped axial through hore 68 [0019] An elongate tensile bar member 82 is positioned Within the durough bore 68, The tensile bar member 82 includes head portion 84 coupled tothe first shal portion 64 ‘an an end portion 86 is coupled tothe second shal portion 66. An annular disk member 90 is carried upon the end por- tion 86 o fasten the tensile bar member 820 the shall portion 66. The tensile bar member 82 connects the shail portions 64 and 66 with spring load from spring 98, anit will be noted that tensile bar member 82 includes a neck portion 102 with a reduced diameter, the function of which will be further described below [0020] The shalt portions 64, 66 each include matching interengageable surfaces 104, 106, respectively. The sures 104, 106 caa include alternating rap and diving surfaces ‘The surfaces 104, 106 are configured such that fist relative torques urge these surfaces into contat and the shat portions ‘Aug, 13, 2009 64, 66 rotate together. On the other hand, the surfaces 104, 106 are configured such tht second relative torques urge the surfaces 104, 106 apart and separate shaft portions 64, 66,08 is depicted by arrow 108. In other words, the surfaces 104, 106 of the shalt portions 64, 66 are configured to rotate together ina first direction, but to separate when the relative torques attempt to rotate the shaft portions 64, 66 in the opposite digection [0021] Having described the structure of the air turbine starter 10, attention may now be given o its operation. During ‘anormal start cycle ofa combustion turbine engine with both the air turbine starter 10 and the engine being stationary, a supply of pressurized fd is connected tothe inet 16 ofthe ti turbine starter 10, Viewing FIG. 1 it will be seen that a flow of pressurized fluid through the housing 12 via the low path 18 will eause the turbine member 20 to extract mech cal power there from and to deliver this power tothe output member 38 ofthe clutch 32 via the gear train 28, The output ‘member 38 drvingly connects with the first shaft portion 64 ofthe decoupled device $8, Engine starting torque applied to the frst shaft portion 64 urges the sufices 104, 106 of the shaft portions 64, 66 into engagement with each other such that the second shaft portion 66 conveys the engine starting povker tothe turbine engine substantially without axial force ‘within the decoupler device $8. Accordingly, the ar turbine starter 10 delivers mechanical power to the decoupler device 58 thoreof, and to the combustion turbine engine connected thereto, to accelerate the latter towards its self-sustaining speed [0022] Upon the combustion turbine engine obtaining its self-sustaining speed, the supply of pressurized ai to flow path 18 is shutoff andthe shaft of the engine will accelerate lead of the output member 38 ofthe air turbine starter 10, Consequently, torque Joading within the eluich 36 will be eliminated, and the starter 10 overruns with respect to the engine. AS result the turbine and drive train sections ofthe tir urbine starter 10 coasts fo a stop and remains stopped {during operation ofthe turbine engine. The output section of the clutch 36 ofthe starter 10 contiaues overruaning as long asthe engine operates, [0023] Certain events may cause a physical malunetion in the air turbine tater 10, For example, one or more of the sprays of clutch 36 flips over center such thatthe turbine engine back drives the air turbine starter 10 10 high and destructive speod, or alternatively, one of the bearings 40 could fail and seize so that a high resisting torque load becomes imposed on the turbine engine, During these types of events, the decoupler device $8 can function to prevent finer damage, Viewing FIG. 2, it will be seen that reverse ‘orque applied tothe shaft portion 66 urges the surfaces 104, 106 apa to result in an axial separation 108 beeen the shalt portions 64, 66. Thereafter, further increased reverse tongue ‘an be transmits from the second shaft portion 660 the fist shaft portion 64 only with the development of a directly related torsion force imposed on teasile bar member 82. The neck portion 102 of tensile bar member 82 is sized such that the member 82 will fail in torsion at a predetermined stress level. That is, the tensile bar member 82 fractures a the neck Portion 102 when a predetermined level of reverse torque is Imposed upon decoupler devioe 88. [024] Asaresultofthe ensilebar member 82 fracturing at the neck portion 102, the shall portions 64, 66 ae allowed to rotate relative tone another in response tothe reverse torque. “The surfaces 104, 106 may additionally move the shaft porUS 2009/0199567 Al tion 64 lefwardly in the view of FIG. 2 andlor the shaft portion 66 rightward i the view of FIG. 2. Inthis position, the surfaces 104, 106 ae disengaged from one another. AS a result ofthe disengagement of the shaft portions 64, 6, the first shat portion 64 and output member 38 of the clutch 36 are no longer driven by the second shalt portion 66, and the second shaft portion 66 rotates relative tothe first shaft por- tion 64 and the output member 38 [0025] One or more bearing stractures can be provided to reduce wear betwoon the socond shaft portion 66 and the ‘output member 38, For example, in the embodiment of FIG. 2, a wear coating 180 is provided between the second shaft Portion 66 nd the output member 38. The coating 150 can be provided on the some oral ofthe outer surfaces ofthe second shaft portion 66, some or all of the inner surfaces of ousput member 38, and/or some oral of both the outer surfices of the second shaft portion 66 and the inner surfaces of the ‘output member 38. The coating 150 can be, for example, a tungsten-cobalt carbide coating or any other coating suitable to reduce weat between the shalt portion 66 and the output member 38, The coating 180 can have a thickness of, for ‘example, 0.005.0.01 inches, although other thicknesses can be provided based on materials of the second sha portion 66 ‘and the output member 38, starter conditions, and/or desired level of wear reduction or prevention. [0026] FIG. 3 is an enlarged crost-sectional view of Starter with a decoupler device 288 in accordance with an tlterate exemplary embodimeat from the decoupler device 58 of FIG. 2. la this embodiment, a bushing 280 is provided to reduce or prevent wear hetween the second shaft portion 266 and the output member 238. The bushing 250 can be a ‘ylindreally shaped sleeve or tube that ean be mounted onthe inner diameter ofthe output meaaber 238 or the outer diam- ter of the shaft 266, The bushing 250 can haveathickness of about 0.080 inches, although ober thickness and shapes ean be provided. The bushing 250 may also serve to constrain or restrict the dynamic movement of the second shaft portion 266. [0027] FIG. 4 is an enlarged crost-sectional view of Starter with decoupler device 388 in accordance with another altemate exemplary embodiment. In this emboci- ‘ment, ball bearing 350 is mounted between the second shalt Portion 366 and the output member 338 to reduce or prevent ‘wear. Aousing element 351 canbe provided o house theball, bearing 380. The ball bearing 350 includes balls 382 and bearingrings 384, Theball bearing 380 may also suppor bath axial and radial dynamic and static Toads between the second sluaft portion 366 aad the output member 338, The ball beat ing 380 can be manufactured fom materials such as AISIS2100 or AISI440C. [0028] FIG. 5 is an enlarged cross-sectional view of starter with # decoupler device 488 in accondance with yet nother altemate exemplary embodiment. In this emboli ment, a roller bearing 480 is mounted between the second shaft portion 466 and the output member 438 to reduce or prevent wear A thrust washer 475 js Tocated between shaft portion 46 and bearing 450, The roller bearing 450 includes rollers 452 and ring 484. The roller bearing 450 in combina- tion with the trust washer 47S may also support oth axial and radial dyoamic and static Hoads between the second shaft portion 466 and the output member 438, The roller bearing 480 can be manufactured fom materials suchas AISIS2100, AISH40C or AISI020, ‘Aug, 13, 2009 [0029] While atleast one exemplary embodiment has been presented in the foregoing detailed description of the inven- ‘ion it should be appreciated that avast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the seope, applicability, or con- figuration ofthe invention in any way. Rather, the foregoing detailed description will provide those skilled inthe a with eoienient road map for implementing an exemplary embodiment ofthe invention, Itheing understood that various changes may be made in the function and arrangement of clements described in an exemplary embodiment without departing from the scope of the invention asset forth in the ‘appended claims. ‘What is claimed is: 1. Anairturbine starter for stating an engine, comprising: ‘housing defining an inlet, an outlet, and a flow path extending between the inlet and the outlet for commu nicating a flow of gas therethrough; ‘turbine member journaled within the housing and dis- posed within the flow path for rotatably extracting ‘mechanieal power from the gs flow; ‘8 gear rain drvingly coupled with the turbine member, ‘clutch coupled with the gear tain and including a output ‘member with an inner surface; a decoupler device at least partially housed within the ‘output member ofthe clutch, the decoupler device com prising a first shat portion coupled to and rotating with, ‘the output member anda second shaft portion coupled to and rotating withthe engine, each ofthe fist and second portions having outer surfaces, the first and second shat portions being aialy aligned and configured wo engage cach another for rotation ina firs direction and to sepa rae from each oherina socond direetionto decouple the ‘output member ofthe elute from the engine; and ‘bearing between the inner surfice ofthe output member and the second shaft portion for reducing ffition ‘between the second shaft portion andthe inner surface of ‘the output member when the first and second shaft por- tions are decoupled. 2. The starter of claim 1, wherein the bearing is positioned ‘on the outer surface ofthe second shat portion, 3. The starter of claim 1, wherein the bearing is a wear coating, 4. The starter of claim 1, wherein the wear eating isa frst ‘wear coating onthe outer surface ofthe second shal portion, ‘and the bearing further comprises a second wear coating on the inner surface ofthe output member. 5, The starter of claim 1, wherein the wear coating has a thickness of about 0.005 inches to about 0.01 inches. 6. The starter of claim 3, wherein the wear coating com- prises a tungsten-cobat carbide coating. 7. The starter of claim 1, wherein second shaft portion has ‘an outer surface, and the bearing i a bushing positioned on the outer surface the sesond shaft portion, 8. The starter of claim 1, wherein the bearing is a ball bearing structure. 9, Te starter of claim 6, whereia te ball bearing structure includes an inner bearing ring arranged onthe outer surface oF the second shaft portion and an outer bearing ring arranged proximate tothe inner surface ofthe output member. 10. The startor of claim 1, wherein the bearing i a roller bearing structureUS 2009/0199567 Al 11. The starter of claim 10, wherein the roller bearing structure incodes bearing ring arangedon the outer surface ‘of the second shaft portion. 12. Thestarter of claim 1, wherein the bearing isconfigured to restrict dynamic movemeat of the second shat portion. 13.A decoupler device for decoupling an output member ‘ofa starter from an engine, the decoupler device comprising ‘first shaft portion configured to be coupled to and rotate with the ouput member; a second shaft portion configured to be coupled to and rofate with the engine, he first and second shaft portions being axially aligned andl configured to engage each nother for rotation ina first direction and to separate from each other ina second direction to decouple the ‘output member from the engine; nd 1 bearing arranged between the output member and the second shaft portion for reducing friction between the second shat portion and the output member when the first and second shaft portions ae decoupled. 14. The device of claim 13, wherein the bearing is posi tioned within an inner surface ofthe output member 15. The device of claim 13, wherein the bearing isa wear coating 16. The device of claim 18, wherein the wear coating has 2 thickness of bout 0.005 inches to about 0.01 inches. 17. The device of claim 13, wherein the bearing isa bush- ing positioned within an inner surface ofthe output member. 18, The device of claim 13, wherein the bearing isa ball- bearing strecture. ‘Aug, 13, 2009 19. The device of claim 13, wherein the bearing is a roller bearing stueture. 20, Anair turbine starter frstartingan engine, comprising: ‘ housing defining an inlet, an outlet, and a flow path extending between the inlet and the outlet for commu nicatng a flow of pas therethrough; ‘turbine member journaled within the housing and dis- posed within the flow path for rotatably extracting ‘mecanieal power from the gas flow: ‘gear rain drvingly coupled with the turbine member, ‘acluch coupled with the gear tain and including an output ‘member having an inner sueface 1 decoupler device atleast partially housed within the ‘output member ofthe clutch, the decoupler deviee com prising a first shaft portion fixed to the output member ‘anda second shaft portion coupled othe engine, each of the fist and second portions having an outer surtace, the fist and seoond shaft portions beng axially aligned and configured to engage each another fr rotation ina first dlirection and to separate from each other ia a second direction 1 decouple the output member ofthe clutch from the engine: and ‘ bushing positioned between the inner surface ofthe out- ‘put member and the second shaft portion for reducing friction between the socond shaft portion and the inner surface of the output member and restrict dynamic ‘movement ofthe secoad shaft portion when the fist and second shat portions are decoupled.