Active Fan Tip Treatment Using Rotating Drum Array

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Solution Overview

Problem

Gas turbine engines experience high distortion due to pressure gradients and swirl, leading to engine stall and undesirable aeromechanical behavior, particularly in embedded applications.

Innovation Solution

A fan case assembly with a plurality of drums and a control unit is used to mitigate pressure and swirl distortions. The drums are positioned in grooves within the fan case and can rotate between closed and open positions to allow or block fluid communication between axial passageways, controlled by the unit in response to operating conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the fan operates in embedded gas turbine engine applications, then the engine can achieve compact integration and versatility, but high distortion in the form of pressure gradients and swirl occurs causing engine stall and undesirable aeromechanical behavior

Engineering Contradiction:
Improveembedded application integrationVSAvoidengine stall margin
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

The patent employs actively controllable tip treatment elements (such as movable tips or adjustable geometry features) that can dynamically change their configuration in response to detected distortion conditions. This dynamic adaptation allows the fan to maintain optimal performance across varying operating conditions while actively mitigating distortion effects, thereby resolving the contradiction between compact integration and stall margin preservation.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The invention utilizes active control systems that detect distortion parameters (pressure gradients, swirl intensity) and adjust fan operating parameters (tip geometry, flow distribution, rotational speed) in real-time. By changing these parameters adaptively, the system maintains reliable operation in embedded applications despite the presence of high distortion, thus improving both adaptability and reliability simultaneously.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If active distortion mitigation systems are implemented in the fan, then stall margin is improved, but device complexity increases

Engineering Contradiction:
Improvestall marginVSAvoidmitigation system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides the tip treatment function into multiple discrete, modular elements distributed around the fan periphery. Each segment can be independently controlled or activated based on local distortion conditions. This segmentation approach enables effective distortion mitigation through localized control while keeping individual element complexity low and allowing for phased implementation, thus reducing overall system complexity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The invention incorporates self-regulating features where the distortion mitigation system automatically detects and responds to distortion conditions without requiring complex external control systems. The tip treatment elements possess inherent feedback mechanisms that enable them to self-adjust their configuration based on local flow conditions, thereby achieving reliable stall margin improvement while minimizing control system complexity.

Inventive Principle:
Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively minimizes the negative effects of pressure and swirl distortions, thereby improving the stall margin of the gas turbine engine by allowing controlled fluid communication and recirculation at the fan tips.

Implementation Method 1

Each drum of the plurality of drums includes a forward portion and an aft portion rotatably connected to the forward portion. The forward portion and aft portion are each shaped to form a respective axial passageway. The forward portion and the aft portion of each drum of the plurality of drums are configured to rotate about a respective drum axis between a closed position and an open position.

Methodology Applied
Scientific EffectFluid communication control through rotational positioning:

Implementation Method 2

The control unit is configured to rotate the plurality of drums about the respective drum axis between the closed position and the open position in response to preselected operating conditions to minimize negative effects pressure and swirl distortions in the gas turbine engine to improve stall margin.

Methodology Applied
Scientific EffectDistortion mitigation through controlled recirculation:

Data Source

PatentUS12209502B1Active fan tip treatment using rotating drum array with axial channels in fan track liner for distortion tolerance
Publication Date: 2025.01.28 ROLLS ROYCE NORTH AMERICAN TECHNOLOGIES INC
  • US12209502B1 patent drawing
  • US12209502B1 patent drawing
  • US12209502B1 patent drawing

AI summary

A gas turbine engine includes a fan and a fan case assembly. The fan includes a fan rotor configured to rotate about an axis of the gas turbine engine and a plurality of fan blades coupled to the fan rotor for rotation therewith. The fan case assembly extends circumferentially around the plurality of fan blades radially outward of the plurality of the fan blades.