Modular Counter-Rotating Propeller System Integration
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Solution Overview
Problem
Counter rotating propeller systems are complex due to integration requirements within engines, limiting their adoption and complicating variable pitch control, which has hindered engine manufacturers from leveraging their benefits.
Innovation Solution
A self-contained modular counter rotating propeller system driven by a gas turbine engine through a reduction gearbox, featuring a separate gear train for counter-rotation and a collective blade angle actuation system with a single actuator to adjust both sets of propeller blades, allowing for independent rotation and pitch control without modifying existing engine or gearbox configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If counter rotating propeller systems are highly integrated within the engine, then the propeller system can be compact, but the device complexity and integration requirements increase significantly
Solution Approach 1:
The propeller system is divided into separate modular components: a first counter-rotating propeller assembly and a second counter-rotating propeller assembly, each with independent hubs, blades, and drive mechanisms. This segmentation allows each module to be designed and manufactured independently, reducing overall integration complexity while maintaining compactness.
Solution Approach 2:
The counter-rotating propeller mechanism is extracted from the traditional engine integration and positioned as a separate system driven by a single shaft through a reduction gearbox. This extraction eliminates the need for complex internal integration within the engine while maintaining the counter-rotating function, thereby reducing device complexity.
2Ease of operation
If multiple actuators are used to control blade angle of both propeller blade sets, then independent control is achieved, but the device complexity and control structure increase
Solution Approach 1:
A single actuator is designed to perform multiple functions by controlling the blade angle of both the first and second propeller blade sets through a translation mechanism. This universal actuator eliminates the need for separate actuators for each propeller set, reducing control structure complexity while maintaining independent control capability.
Solution Approach 2:
A translation mechanism serves as an intermediary between the single actuator and the two propeller blade sets. This intermediary converts the actuator's motion into appropriate blade angle adjustments for both propeller sets, enabling controlled operation without requiring multiple actuators.
3Productivity
If the propeller system is modified to enable counter-rotation, then propulsion efficiency improves, but the ease of manufacture and integration with existing engines decreases
Solution Approach 1:
The system uses segmented propeller assemblies that can be manufactured as separate modules and then assembled. Each assembly includes its own hub, blades, and drive components, allowing for standardized manufacturing processes and simplifying integration with existing engines through modular installation.
Solution Approach 2:
The counter-rotating propeller mechanism is extracted as a separate system that interfaces with the existing engine through a single shaft connection and reduction gearbox. This extraction approach maintains propulsion efficiency while avoiding the need to modify existing engine components, thereby improving ease of manufacture and integration.
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 solution simplifies the integration and control of counter rotating propeller systems, enabling efficient operation within existing engine platforms with reduced complexity and no need for additional modifications, allowing for optimized performance and flexibility in torque distribution between propeller blades.
Implementation Method 1
A gear train housed separate from the reduction gearbox provides the counter-rotation of a first and second pluralities of propeller blades
Implementation Method 2
The example collective blade control system includes a single actuator to control blade angle of both the first and second plurality of propeller blades
Implementation Method 3
A translation mechanism is provided for communicating blade angle changes between the first and second plurality of propeller blades
Data Source
Figure 1
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Figure 4~5
AI summary
A self-contained counter rotating turbo prop system (14) is driven by a gas turbine engine (10) through a reduction gearbox (12). A gear train housed separate from the reduction gearbox (12) provides the counter-rotation of a first and second pluralities of propeller blades (18,20). The entire counter-rotating propeller system (14) is disposed within cowlings (16A,16B) and is separate from the gas turbine engine (10) and reduction gearbox (12). The counter rotating propeller system (14) includes a collective blade angle actuation system (55) that provides for adjustment of blade angle of both the first and second plurality of propeller blades (18,20) with a single actuator.