Turbofan Bypass Structure with Removable Front Frame
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Solution Overview
Problem
The existing turbofan engines have a high weight due to multiple assembly interfaces and a heavy front frame structure, which increases manufacturing and assembly time, disrupts airflow, and contributes to overall weight and cost, while also requiring complex manufacturing techniques.
Innovation Solution
A cylindrical single-piece bypass structure is designed coaxially with the engine centerline, and a front frame structure with radially extending centering lugs is slidably installed within this structure, reducing the number of assembly interfaces and using lightweight materials to minimize weight and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple assembly interfaces with opposing flanges are used to connect components, then structural strength and reliability are improved, but device complexity and manufacturing time increase
Solution Approach 1:
The patent merges multiple separate bypass components (forward bypass, aft bypass, fan containment housing) into a single integrated bypass structure. This consolidation eliminates the assembly interfaces between these components, reducing device complexity while maintaining structural strength through the unified design. The single-piece structure removes the need for multiple flange connections and bolting operations.
Solution Approach 2:
The patent segments the front frame structure from the bypass structure, allowing the front frame to be a separate removable component while the bypass remains integrated. This segmentation enables the front frame to be independently manufactured and installed, simplifying the overall assembly process while maintaining the structural integrity needed for engine mounting and support.
2Strength
If multiple assembly interfaces with opposing flanges are used to connect components, then structural strength is improved, but manufacturing and assembly time increase
Solution Approach 1:
The integration of forward bypass, aft bypass, and fan containment housing into a single structure eliminates multiple manufacturing steps and assembly operations. The unified bypass structure requires only single-piece manufacturing processes and minimal assembly operations, dramatically reducing manufacturing and assembly time while maintaining the structural strength required for engine operation.
3Stability of the object's composition
If multiple assembly interfaces are used to connect components, then structural integrity is maintained, but airflow disruption increases
Solution Approach 1:
The single-piece bypass structure eliminates the flange interfaces that create steps and gaps in the airflow path. The continuous smooth surface of the integrated bypass allows uninterrupted airflow from the fan outlet through the bypass duct, reducing turbulence and improving aerodynamic efficiency while maintaining structural integrity through the unified construction.
4Strength
If a heavy front frame structure with circumferential rings is used, then structural strength for engine mounting is improved, but overall engine weight increases
Solution Approach 1:
The integration of the front frame with the bypass structure allows for optimized material distribution and reduced redundancy. The unified structure can be designed with precise material placement where strength is needed, eliminating the need for heavy circumferential rings while maintaining the structural strength required for engine mounting and support.
Solution Approach 2:
The patent enables the use of composite materials or optimized metal alloys in the integrated front frame and bypass structure. These materials provide high strength-to-weight ratios, allowing the structure to maintain the required structural strength for engine mounting while significantly reducing the overall weight compared to traditional heavy metal constructions.
5Strength
If a heavy front frame structure with circumferential rings is used, then structural strength for supporting engine weight is improved, but manufacturing complexity increases
Solution Approach 1:
The integrated front frame and bypass structure can be manufactured as a single piece using modern manufacturing processes such as composite molding or advanced machining. This eliminates the need for complex assembly procedures involving multiple circumferential rings and their associated fastening operations, significantly simplifying manufacturing while maintaining the structural strength needed to support engine weight.
Data Source
AI summary
A system and method is provided that combines fan bypass components and minimizes assembly interfaces in a turbofan engine. The system and method provide a front frame structure of reduced weight that slidably installs/removes from within the combined fan bypass components.