Modular Aircraft Engine Assembly with Segmented Casings
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Solution Overview
Problem
Compound engine assemblies, particularly supercharged or turbocharged engines, are bulky and difficult to integrate into existing aircraft nacelles, posing challenges for adaptation in aircraft applications.
Innovation Solution
The design of an aircraft engine assembly with a modular configuration, including a gearbox module, compressor module, and turbine module, where each module is encased independently and can be detached for maintenance, with the turbine shaft rotationally supported within the gearbox module casing, eliminating the need for lubricant circulation within the compressor and turbine modules, and optimizing module speeds for performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a compound engine assembly with integrated compressor and turbine is used, then power output is improved, but the assembly becomes bulky and difficult to integrate into aircraft nacelles
Solution Approach 1:
The engine assembly is divided into separate modular components: a compressor module with its own casing, a turbine module with its own casing, and a gearbox module. Each module can be independently manufactured, maintained, and replaced. The compressor module includes a compressor rotor mounted on a shaft with bearings contained within the compressor casing, while the turbine module includes a turbine rotor on a separate shaft with bearings in the turbine casing, eliminating the need for a single bulky integrated housing.
2Strength
If traditional integrated engine design is used, then structural integrity is maintained, but maintenance accessibility and ease of repair are reduced
Solution Approach 1:
The engine assembly is divided into separate modular components: a compressor module with its own casing, a turbine module with its own casing, and a gearbox module. Each module can be independently manufactured, maintained, and replaced. The compressor module includes a compressor rotor mounted on a shaft with bearings contained within the compressor casing, while the turbine module includes a turbine rotor on a separate shaft with bearings in the turbine casing, eliminating the need for a single bulky integrated housing.
3Reliability
If lubricant is circulated throughout the entire engine assembly, then all bearings are lubricated, but the risk of fire increases and maintenance complexity increases
Solution Approach 1:
The engine assembly is divided into separate modular components: a compressor module with its own casing, a turbine module with its own casing, and a gearbox module. Each module can be independently manufactured, maintained, and replaced. The compressor module includes a compressor rotor mounted on a shaft with bearings contained within the compressor casing, while the turbine module includes a turbine rotor on a separate shaft with bearings in the turbine casing, eliminating the need for a single bulky integrated housing.
Solution Approach 2:
The lubrication system is extracted and localized to the gearbox module only. The compressor module and turbine module do not require lubricant circulation, as their bearings are either lubricated through the gearbox module's lubrication system or designed to operate without additional lubricant circulation. This extraction of the lubrication function to a specific module reduces fire risk and simplifies maintenance.
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 modular design reduces the engine's bulk, facilitates easier integration into aircraft nacelles, enhances maintenance accessibility, and allows for optimized performance by ensuring each module operates at its optimal speed, while minimizing the risk of fire and improving structural integrity.
Implementation Method 1
a turbine section having an inlet in fluid communication with an outlet of the engine core, the turbine section including at least one turbine rotor connected to a turbine shaft
Implementation Method 2
a compressor having an outlet in fluid communication with an inlet of the engine core, the compressor including at least one compressor rotor in driving engagement with at least one of the turbine shaft and the engine shaft
Data Source
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AI summary
An engine assembly including an engine core with at least one internal combustion engine, a first casing, a turbine module including a second casing located outside of the first casing, and a compressor module including a third casing located outside of the first and second casings. The turbine shaft extends into the first casing, is rotationally supported by a bearings all contained within the first casing, and is free of rotational support within the second casing. The first casing may be a gearbox module casing through which the turbine shaft is in driving engagement with the engine shaft. A method of driving a rotatable load of an aircraft, and an engine assembly with a rotary engine core, a gearbox module with a first casing, and a second module including a second casing located outside of the first casing and detachably connected to the first casing are also discussed.