Turbine Engine Core Design for Variable Thrust Ratings
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Solution Overview
Problem
Current turbine engines, such as geared turbofan engines, lack the capability to efficiently produce different thrust ratings with minimal variations in design and manufacturing costs, requiring significant modifications for each thrust rating configuration.
Innovation Solution
The design of a turbine engine with a multi-spool core and gear train configuration that allows for the production of engines with different thrust ratings by utilizing a common set of components, where the upstream-most set of compressor blades define areas within 20% of each other, enabling the manufacturing of engines with substantially similar core structures and components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If turbine engines are designed with different thrust ratings, then thrust capability is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent applies universality by designing a common engine core structure that can serve multiple thrust rating configurations. The core including compressor, combustor, and turbine assemblies is standardized to produce a common core airflow, allowing the same core to support different fan rotor options (single-spool, two-spool, three-spool) and different gear train configurations. This enables one core design to fulfill multiple thrust rating requirements without redesigning the entire engine.
Solution Approach 2:
The patent segments the engine into modular components: a standardized core module and variable thrust modules (fan rotors, gear trains). The core is separated into distinct functional segments (compressor section, combustor, turbine section) that can be kept identical across different thrust ratings, while the fan rotor and gear train segments are varied to achieve different thrust outputs. This segmentation allows independent optimization and manufacturing of common parts.
2Power
If turbine engines are designed with different thrust ratings, then thrust capability is improved, but manufacturing costs increase
Solution Approach 1:
The standardized core design serves as a universal platform that can be manufactured once and used across multiple thrust rating variants. The common core components (compressor blades, combustor housing, turbine blades) can be produced in larger volumes for a single design, achieving economies of scale. The same core is then configured with different fan rotors and gear trains to create engines with different thrust ratings, reducing per-unit manufacturing costs.
Solution Approach 2:
The patent enables recovery and reuse of the common core components across different engine variants. Instead of manufacturing entirely new engines for each thrust rating, the core is recovered from the design process and reused with different peripheral components. This reduces material waste and manufacturing expenses for the shared core structure.
3Power
If turbine engines are designed with different thrust ratings, then thrust capability is improved, but research and development time increases
Solution Approach 1:
The standardized core provides a universal foundation that eliminates the need to redesign the entire engine for each thrust rating. The core design, including aerodynamic pathways and component interfaces, is established once and then reused across multiple thrust rating configurations. This reduces R&D time by focusing development efforts only on the variable components (fan rotors, gear trains) rather than the entire engine system.
Solution Approach 2:
The patent performs preliminary design and validation of the core structure in advance, establishing a proven platform before configuring specific thrust rating variants. The core's airflow paths, component clearances, and operational parameters are predetermined and validated, so that when different fan rotors or gear trains are added, the core is already optimized and ready. This preliminary action on the common core significantly accelerates the development of new thrust rating variants.
Data Source
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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.