Common-Core Turbine Engine Architecture for Multiple Thrust Ratings
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current turbine engines, such as geared turbofan engines, lack efficiency in producing different thrust ratings, requiring significant modifications and increased costs due to the need for distinct configurations and components for varying thrust requirements.
Innovation Solution
The design includes a turbine engine configuration with multiple rotating assemblies and a gear train, allowing for the production of turbine engines with different thrust ratings using a common set of components, where the upstream-most compressor blades' areas differ by no more than 20%, and the engine case structures have identical geometries and dimensions, enabling efficient manufacturing and reduced development and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If distinct configurations and components are used for varying thrust requirements, then different thrust ratings can be achieved, but manufacturing complexity and costs increase significantly
Solution Approach 1:
The patent applies universality by designing a common engine core structure that can serve multiple thrust rating configurations. The engine case structure, mounting patterns, and core components are standardized to be used across different thrust variants, allowing the same basic design to fulfill multiple functions with different thrust outputs through modular component variations.
Solution Approach 2:
The patent applies segmentation by dividing the engine into modular components - a common core structure and separate thrust-specific modules. This allows different thrust ratings to be achieved by configuring or replacing specific modules (such as fan assemblies, compressor sections, or turbine components) while retaining the common core, thereby reducing overall configuration complexity.
2Adaptability or versatility
If distinct configurations and components are used for varying thrust requirements, then different thrust ratings can be achieved, but manufacturing costs increase
Solution Approach 1:
The patent reduces manufacturing costs by establishing a universal engine core that can be produced in larger volumes for multiple thrust variants. This increases production efficiency and reduces per-unit costs through economies of scale, while still allowing customization for different thrust ratings through modular component variations.
Solution Approach 2:
The patent merges common structural elements and systems across different thrust variants into a single standardized design. By combining the engine case, mounting structures, and core components into a unified platform, the patent eliminates redundant manufacturing processes and reduces overall production costs while maintaining the ability to produce different thrust ratings.
3Productivity
If common components are used across different thrust ratings, then manufacturing efficiency improves, but thrust rating differentiation becomes more challenging
Solution Approach 1:
The patent maintains thrust rating differentiation by segmenting the engine into common core components and thrust-specific modules. This segmentation allows the common components to be manufactured efficiently in large volumes while the thrust-specific modules can be varied to achieve different thrust ratings, thus preserving adaptability without sacrificing manufacturing efficiency.
Solution Approach 2:
The patent applies local quality by maintaining uniform common components across all thrust variants while allowing specific local areas (such as fan blade geometry, compressor blade profiles, or turbine nozzle configurations) to vary according to the required thrust rating. This ensures that the majority of components can be produced efficiently with consistent quality standards while still achieving the necessary performance differentiation.
Data Source
AI summary
A method is provided that includes providing a first turbine engine and providing a second turbine engine. The first turbine engine is configured with a first thrust rating. The first turbine engine includes a first engine rotating assembly and a first engine case structure housing at least the first engine rotating assembly. The second turbine engine is configured with a second thrust rating that is different than the first thrust rating. The second turbine engine includes a second engine rotating assembly and a second engine case structure housing at least the second engine rotating assembly. The first engine case structure and the second engine case structure have at least substantially common configurations. The first turbine engine and the second turbine engine are provided by a common entity.