Flexible Coupling Shaft Layout for Turbine Engine Gearbox Connection
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Solution Overview
Problem
Turbine engines face challenges in increasing efficiency, reducing fuel consumption, and minimizing noise while managing torque and power output variations, which can lead to deformations and overspeed conditions, and existing gearbox configurations often increase packaging dimensions and complicate torque paths.
Innovation Solution
A turbine engine design incorporating a flexible coupling shaft with splines and speed/torque sensors, connecting the engine core to the gearbox, allowing for axial and radial deformation while separating torque and speed sensing paths, thereby improving response to intermittent torque changes and reducing packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid coupling is used between engine core and gearbox, then torque transmission is efficient, but the system cannot accommodate intermittent torque changes and deformations
Solution Approach 1:
The patent applies the dynamics principle by replacing the rigid coupling with a flexible coupling shaft that can dynamically adapt to torque variations. The flexible coupling shaft is designed to bend and deform elastically in response to intermittent torque changes from the engine core, allowing the system to accommodate dynamic loading conditions while maintaining reliable power transmission. This dynamic flexibility prevents stress concentration and potential failure that would occur with a rigid coupling.
2Reliability
If a flexible coupling is used between engine core and gearbox, then the system can accommodate torque variations, but torque transmission efficiency decreases
Solution Approach 1:
The patent applies parameter changes by carefully controlling the flexibility parameters of the coupling shaft. The shaft is designed with specific material properties, cross-sectional dimensions, and length to achieve optimal balance between flexibility and efficiency. By adjusting these parameters, the shaft provides sufficient flexibility to accommodate torque variations while minimizing elastic deformation energy losses, thus maintaining high torque transmission efficiency.
3Volume of moving object
If the gearbox is positioned closer to the engine core, then packaging is reduced, but torque path length decreases affecting response time
Solution Approach 1:
The flexible coupling shaft acts as an intermediary element between the engine core and gearbox. It serves dual functions: mechanically transmitting torque while providing flexibility to accommodate deformations, and sensorially mediating by housing speed and torque sensors that monitor power transmission in real-time. This intermediary role allows the system to maintain compact packaging with the gearbox positioned close to the engine core while the sensors provide timely detection of torque variations.
4Measurement precision
If speed sensors are placed on the torque path, then speed monitoring is accurate, but the torque path becomes more complex and response time increases
Solution Approach 1:
The patent applies merging by integrating the speed and torque sensors directly into the flexible coupling shaft structure. The sensors are embedded within the shaft or mounted on its surface, combining the sensing function with the mechanical coupling function. This integration eliminates separate sensing components and complex mounting structures, reducing overall system complexity while maintaining accurate real-time monitoring of speed and torque parameters on the power transmission path.
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 design enhances the turbine engine's response to deformations and overspeed conditions, reduces packaging, and optimizes torque paths, leading to improved efficiency and reduced noise output.
Implementation Method 1
a flexible coupling shaft defining a first end and a second end along the axial direction, wherein the first end is connected to the engine core and the second end is connected to the gearbox, and further wherein the flexible coupling shaft extends from the one or more rotors to the gearbox in the axial direction and inward of the hub in the radial direction
Data Source
AI summary
The present disclosure is directed to a turbine engine (10) defining an axial direction and a radial direction. The turbine engine includes a fan or propeller assembly (14) comprising a gearbox; an engine core (20) comprising one or more rotors, wherein at least one of the rotors defines an axially extended annular hub; and a flexible coupling shaft (100) defining a first end and a second end along the axial direction, wherein the first end is connected to the engine core and the second end is connected to the gearbox, and further wherein the flexible coupling shaft extends from the one or more rotors to the gearbox in the axial direction and inward of the hub in the radial direction.