High power epicyclic gearbox and operation thereof

Patent metadata

Field	Value
Publication number	US-12359628-B2
Application number	US-202418829971-A
Country	US
Kind code	B2
Filing date	Sep 10, 2024
Priority date	May 12, 2019
Publication date	Jul 15, 2025
Grant date	Jul 15, 2025

Abstract

A gas turbine engine for an aircraft including: an engine core including a turbine, a compressor, and a core shaft connecting the turbine to the compressor; a fan located upstream of the engine core, the fan including a plurality of fan blades; a gearbox that can receive an input from the core shaft, and can output drive to a fan shaft via an output of the gearbox so as to drive the fan at a lower rotational speed than the core shaft; and a fan shaft mounting structure arranged to mount the fan shaft within the engine, the fan shaft mounting structure including at least two supporting bearings connected to the fan shaft.

First claim

The invention claimed is:

1. A gas turbine engine for an aircraft comprising:
an engine core comprising a turbine, a compressor, and a core shaft connecting the turbine to the compressor;
a fan located upstream of the engine core, the fan comprising a plurality of fan blades;
a gearbox that is configured to:
receive an input from the core shaft, and
output drive to a fan shaft via an output of the gearbox so as to drive the fan at a lower rotational speed than the core shaft; wherein
a product of: (a radial bending stiffness of the fan shaft at the input to the fan)×(a radial bending stiffness of the fan shaft at the output of the gearbox)

is greater than or equal to 1.2×10 13 (N/m) 2 .

2. The gas turbine engine according to claim 1 , wherein the product of:
(the radial bending stiffness of the fan shaft at the input to the fan)×(the radial bending stiffness of the fan shaft at the output of the gearbox)

is greater than or equal to 2.4×10 14 (N/m) 2 .

3. The gas turbine engine according to claim 1 , wherein the product of:
(the radial bending stiffness of the fan shaft at the input to the fan)×(the radial bending stiffness of the fan shaft at the output of the gearbox)

is less than or equal to 3.0×10 18 (N/m) 2 .

4. The gas turbine engine according to claim 1 , wherein the product of:
(the radial bending stiffness of the fan shaft at the input to the fan)×(the radial bending stiffness of the fan shaft at the output of the gearbox)

is less than or equal to 3.0×10 17 (N/m) 2 .

5. The gas turbine engine according to claim 1 , wherein the gearbox has a gear ratio of greater than 3.6.

6. The gas turbine engine according to claim 1 , wherein the gearbox has a gear ratio in a range of 3.7 and 4.4.

7. The gas turbine engine according to claim 1 , further comprising a bypass duct radially outside the engine core,
wherein a bypass ratio, which is defined as the ratio of a mass flow rate of the flow through the bypass duct to a mass flow rate of the flow through the engine core, is in a range of 13 to 17 at cruise conditions.

8. The gas turbine engine according to claim 1 , wherein at least one of the following is satisfied:
the moment of inertia of the fan is in a range from 7.40×10 7 kgm 2 to 9.00×10 8 kgm 2 ;
the fan comprises 18 or 20 fan blades;
each fan blade comprises a carbon-fibre or aluminium based body with a titanium leading edge; and
the material from which the fan shaft is made has a Young's modulus in a range from 105 to 215 GPa.

9. The gas turbine engine according to claim 1 , further comprising a bypass duct radially outside the engine core, wherein:
the gearbox has a gear ratio in a range of 3.6 and 4.4;
a bypass ratio, which is defined as the ratio of a mass flow rate of the flow through the bypass duct to a mass flow rate of the flow through the engine core, is in a range of 13 to 16 at cruise conditions;
a fan tip loading defined as dH/U tip 2 , where dH is an enthalpy rise across the fan and U tip is a translational velocity of the fan tip, is in a range from 0.29 to 0.35 at cruise conditions; and
an overall pressure ratio defined as the ratio of a stagnation pressure upstream of the fan to a stagnation pressure at the exit of a highest pressure compressor section of the compressor is in a range of 45 to 60 at cruise conditions.

10. The gas turbine engine according to claim 9 , wherein at least one of the following is satisfied:
the fan has a diameter in a range of 220 cm to 230 cm;
a maximum net thrust of the gas turbine engine at standard atmospheric conditions at sea level plus 15 degrees C. with the engine static is no greater than 170 kN; and
a specific thrust of the gas turbine engine, defined as a net thrust of the engine divided by a total mass flow through the engine, is in a range from 80 Nkg −1 s to 90 Nkg −1 s at cruise conditions.

11. The gas turbine engine according to claim 1 , wherein at least one of the following is satisfied: the radial bending stiffness of the fan shaft at the input to the fan is in a range from 3.00×10 6 N/m to 2.00×10 9 N/m; and the radial bending stiffness of the fan shaft at the output of the gearbox is in a range from 4.00×10 6 N/m to 1.5×10 9 N/m.

12. The gas turbine engine according to claim 1 , wherein a product of: (a tilt stiffness of the fan shaft at the input to the fan)×(a tilt stiffness of the fan shaft at the output of the gearbox) is greater than or equal to 3.5×10 10 (Nm/rad) 2 .

13. The gas turbine engine according to claim 1 , further comprising a fan shaft mounting structure arranged to mount the fan shaft within the engine, the fan shaft mounting structure comprising at least two supporting bearings connected to the fan shaft, wherein at least one of the following is satisfied:
an axial distance between an input to the fan and a closest bearing of the at least two supporting bearings in a rearward direction from the fan is in a range from 0.12 m to 0.40 m; and
an axial distance between a fan input position and a gearbox output position is in a range from 0.43 m to 0.95 m.

14. A gas turbine engine for an aircraft comprising:
an engine core comprising a turbine, a compressor, and a core shaft connecting the turbine to the compressor;
a fan located upstream of the engine core, the fan comprising a plurality of fan blades;
a gearbox that is configured to:
receive an input from the core shaft, and
output drive to a fan shaft via an output of the gearbox so as to drive the fan at a lower rotational speed than the core shaft; wherein

a product of:
(a tilt stiffness of the fan shaft at the input to the fan)×(a tilt stiffness of the fan shaft at the output of the gearbox)

is greater than or equal to 3.5×10 10 (Nm/rad) 2 .

15. The gas turbine engine according to claim 14 , wherein the product of:
(the tilt stiffness of the fan shaft at the input to the fan)×(the tilt stiffness of the fan shaft at the output of the gearbox)

is less than or equal to 5.0×10 16 (Nm/rad) 2 .

16. The gas turbine engine according to claim 14 , wherein the gearbox has a gear ratio in a range of 3.6 and 4.4.

17. The gas turbine engine according to claim 14 , further comprising a bypass duct radially outside the engine core,
wherein a bypass ratio, which is defined as the ratio of a mass flow rate of the flow through the bypass duct to a mass flow rate of the flow through the engine core, is in a range 13 to 16 at cruise conditions.

18. The gas turbine engine according to claim 14 , wherein at least one of the following is satisfied:
the tilt stiffness of the fan shaft at the input to the fan is in a range from 5.00×10 5 Nm/rad to 7.00×10 8 Nm/rad; and
the tilt stiffness of the fan shaft at the output of the gearbox is in a range from 7.00×10 4 Nm/rad to 7.00×10 7 Nm/rad.

19. The gas turbine engine according to claim 14 , wherein:
the fan comprises 16, 18, 20 or 22 fan blades;
each fan blade comprises a carbon-fibre or aluminium based body with a titanium leading edge;
the material from which the fan shaft is made has a Young's modulus in a range from 105 to 215 GPa;
the ratio of the radius of a fan blade at its hub to the radius of the fan blade at its tip is in a range from 0.25 to 0.31;
the gas turbine engine comprises a bypass duct radially outside the engine core and a bypass ratio is defined as the ratio of a mass flow rate of the flow through the bypass duct to a mass flow rate of the flow through the engine core is in a range of 13 to 16 at cruise conditions;
the gearbox has a gear r

Assignees

• Rolls Royce Plc

Inventors

• Spruce Mark

Classifications

• F05D2200/14

  Division · CPC title

• F05D2220/36

  specially adapted for the fan of turbofan engines · CPC title

• F05D2220/323

  for aircraft propulsion, e.g. jet engines · CPC title

• F05D2260/40311

  of the epicyclical, planetary or differential type · CPC title

• F02K3/06

  with front fan · CPC title