Boost Spool Gearbox With Differential Power Split for Low-Power Operation
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Solution Overview
Problem
Turbine engines face inefficiencies in power generation during low and partial power conditions, as existing systems lack effective mechanisms to optimize power distribution between core and boost spools and accessory gearboxes.
Innovation Solution
A differential gear system is introduced, coupling a core engine with a boost spool and accessory gearbox, featuring a first and second differential gear, a rotatable differential carrier, and a boost spool clutch, allowing for selective power distribution and torque input to the accessory gearbox and tower shaft, enabling different operating configurations to augment engine performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional direct drive system is used between the core engine and accessory gearbox, then the structure is simple, but power generation efficiency deteriorates during low and partial power conditions
Solution Approach 1:
The patent introduces a dynamic power distribution system using a differential gear system that can adaptively adjust power flow between the core engine, boost spool, and accessory gearbox based on operating conditions. The differential carrier and planet gears enable continuous variation of power split ratios, transforming a static direct-drive system into a dynamic one that optimizes efficiency across different power levels.
Solution Approach 2:
The differential gear system serves multiple functions simultaneously: it acts as a power splitter, a torque amplifier, and a speed matcher. The same mechanism can operate in different modes (series hybrid, parallel hybrid, direct drive) depending on clutch engagement, providing universal adaptability across various operating conditions while maintaining a single integrated structure.
2Productivity
If a boost spool system is added to augment engine power, then power generation efficiency improves, but device complexity increases
Solution Approach 1:
The patent merges the boost spool system with the accessory gearbox drive system through a unified differential gear mechanism. Instead of separate independent systems, the boost spool and core engine are integrated into a single differential assembly where power from both sources is combined and distributed to the accessory gearbox, reducing overall system complexity despite adding boost capability.
Solution Approach 2:
The differential gear system acts as an intermediary mechanism that mediates between the core engine and boost spool, and between them and the accessory gearbox. This intermediary structure provides a flexible interface that allows smooth power transfer and distribution without requiring complex direct couplings between all components.
3Adaptability or versatility
If a differential gear system is introduced for flexible power distribution, then adaptability to different operating conditions improves, but device complexity increases
Solution Approach 1:
The differential gear system is segmented into modular functional units: the differential carrier assembly, planet gear set, ring gear, and associated clutch mechanisms. This segmentation allows each component to perform a specific function while maintaining overall system flexibility, and enables independent maintenance or replacement of individual modules without affecting the entire system.
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
This configuration enhances power generation efficiency by allowing tailored power distribution between the core engine, boost spool, and accessory gearbox, improving engine performance during low and partial power conditions through strategic engagement of brakes and clutches.
Implementation Method 1
A differential gear system is coupled between the core engine, the boost spool and the accessory gearbox for distributing power between the boost spool, the core engine and the accessory gearbox
Data Source
AI summary
A turbine engine includes a core engine including a first spool and a second spool rotatable about a main engine longitudinal axis, a boost spool powered by a secondary drive system, and an accessory gearbox coupled to the core engine and the boost spool. A differential gear system is coupled between the core engine, the boost spool and the accessory gearbox for distributing power between the boost spool, the core engine and the accessory gearbox.