Epicyclic Gearbox Input Shaft Stiffness for Load Isolation

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Solution Overview

Problem

Aircraft gas turbine engines with epicyclic gearboxes face challenges in maintaining gearbox isolation from excessive loads while ensuring deflections remain within acceptable levels, particularly due to the interplay between tilt and radial bending stiffness of the gearbox input shaft, which can lead to uneven load distribution and gear damage.

Innovation Solution

The gearbox input shaft is designed with specific ranges of tilt and radial bending stiffness to isolate the gearbox from excessive loads, with tilt stiffness being more critical than radial bending stiffness, and adjustments in shaft properties such as diameter, material, and wall thickness are made to achieve these stiffness values, ensuring the gearbox operates within defined parameters at cruise conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the tilt stiffness of the gearbox input shaft is increased to reduce deflections, then the gearbox isolation from excessive loads is improved, but the load distribution uniformity deteriorates

Engineering Contradiction:
Improvegearbox isolationVSAvoidload distribution uniformity
Core Design Contradiction:
ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent applies parameter changes by optimizing the tilt stiffness within a specific range (5×10^4 to 5×10^6 Nm/radian) rather than maximizing it. This controlled parameter adjustment ensures the shaft provides sufficient isolation from excessive loads while maintaining acceptable deflection levels that preserve load distribution uniformity across planet gears.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent applies local quality by differentiating the importance of stiffness properties - tilt stiffness is given higher priority (5-10 times more important than radial bending stiffness) based on its greater impact on load distribution. The shaft is designed with specific local properties (tilt stiffness in the optimized range) at critical locations to achieve the desired balance between isolation and uniformity.

Inventive Principle:
Principle #3Local quality

2Reliability

If the radial bending stiffness of the gearbox input shaft is increased to reduce deflections, then the gearbox isolation from excessive loads is improved, but the device complexity increases

Engineering Contradiction:
Improvegearbox isolationVSAvoidshaft design complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by establishing a specific range for radial bending stiffness (6×10^5 to 3×10^7 N/m) and prioritizing tilt stiffness optimization over radial bending stiffness. This approach achieves gearbox isolation through the more critical tilt stiffness parameter, avoiding the need for complex shaft designs that would be required to achieve isolation solely through radial bending stiffness increases.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent applies the extraction principle by separating the two stiffness parameters (tilt stiffness and radial bending stiffness) and treating them independently with different priority levels. By extracting tilt stiffness as the primary isolation mechanism and radial bending stiffness as a secondary parameter, the design avoids the complexity that would arise from optimizing both parameters equally.

Inventive Principle:
Principle #2Taking out (Extraction)

3Reliability

If the shaft diameter is increased to increase stiffness, then the gearbox isolation is improved, but the weight of the shaft increases

Engineering Contradiction:
Improvegearbox isolationVSAvoidshaft weight
Core Design Contradiction:
ReliabilityVSWeight of moving object

Solution Approach 1:

The patent applies parameter changes by optimizing the shaft's stiffness parameters (tilt stiffness and radial bending stiffness) within specific ranges rather than simply increasing diameter. This allows achieving the required gearbox isolation through material selection, wall thickness adjustment, and geometric optimization, thereby avoiding excessive weight increase that would result from simply enlarging the shaft diameter.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS11781487B2High power epicyclic gearbox and operation thereof
Publication Date: 2023.10.10 ROLLS ROYCE PLC
  • US11781487B2 patent drawing
  • US11781487B2 patent drawing
  • US11781487B2 patent drawing

AI summary

A gas turbine engine for an aircraft includes an engine core with a turbine, a compressor, and a core shaft connecting the turbine and compressor; a fan upstream of the engine core including a plurality of fan blades; and a gearbox that receives an input from a gearbox input shaft portion of the core shaft and outputs drive to a fan shaft so as to drive the fan at a lower rotational speed than the core shaft, the gearbox being an epicyclic gearbox including a sun gear, a plurality of planet gears, a ring gear, and a planet carrier arranged to have the plurality of planet gears mounted thereon, and wherein the sun gear receives input from the core shaft. At cruise conditions the torque on the core shaft is greater than 10,000 Nm and a ratio of core shaft stiffness to core shaft torque is within a specified range.