Geared gas turbine engine and a gearbox
10458274 ยท 2019-10-29
Assignee
Inventors
Cpc classification
F05D2300/174
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/2282
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/171
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2220/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/6032
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/005
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H57/082
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/2261
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/40311
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T50/60
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F01D25/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C7/36
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D15/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/2283
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H1/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H57/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01D25/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H1/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H57/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C7/36
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D15/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A gas turbine engine comprises a gearbox comprises a sun gear, an annulus gear, a plurality of planet gears and a carrier. The sun gear meshes with the planet gears and the planet gears mesh with the annulus gear. The planet gear carrier comprising a first ring, a second ring spaced axially from the first ring and a plurality of circumferentially spaced axles extending axially between the first ring and the second ring. Each planet gear is rotatably mounted on a respective one of the axles and the axles are arranged at a first radius. At least one of the first ring and the second ring comprises a metal matrix composite material ring and the metal matrix composite ring comprises a ring of reinforcing fibres and the ring of reinforcing fibres having a second radius greater than the first radius.
Claims
1. A gas turbine engine comprising a gearbox, the gearbox comprising: a sun gear; an annulus gear; a plurality of planet gears; and a carrier, the sun gear meshing with the planet gears and the planet gears meshing with the annulus gear; the carrier comprising a first ring, a second ring spaced axially from the first ring, and a plurality of circumferentially spaced axles extending axially between the first ring and the second ring; each planet gear being rotatably mounted on a respective one of the plurality of circumferentially spaced axles; each of the plurality of circumferentially spaced axles being arranged at a first radius; at least one of the first ring and the second ring comprising a metal matrix composite material; the metal matrix composite material comprising a ring of reinforcing fibres; and the ring of reinforcing fibres having a second radius greater than the first radius.
2. A gas turbine engine as claimed in claim 1, wherein the first ring comprises a first metal matrix composite material and the second ring comprises a second metal matrix composite material; the first metal matrix composite material comprises a first ring of reinforcing fibres, the first ring of reinforcing fibres having a second radius greater than the first radius; and the second metal matrix composite material comprises a second ring of reinforcing fibres, the second ring of reinforcing fibres having a second radius greater than the first radius.
3. A gas turbine engine as claimed in claim 2, wherein the first ring and the second ring are secured together.
4. A gas turbine engine as claimed in claim 2, wherein the first metal matrix composite material comprises a metal matrix selected from a group consisting essentially of a steel matrix, a titanium matrix, and a titanium alloy matrix.
5. A gas turbine engine as claimed in claim 2, wherein the first metal matrix composite material comprises reinforcing fibres selected from a group consisting essentially of silicon carbide fibres, silicon nitride fibres, and boron nitride fibres.
6. A gas turbine engine as claimed in claim 2, wherein the second metal matrix composite material comprises a metal matrix selected from a group consisting essentially of a steel matrix, a titanium matrix, and a titanium alloy matrix.
7. A gas turbine engine as claimed in claim 2, wherein the second metal matrix composite material comprises reinforcing fibres selected from a group consisting essentially of silicon carbide fibres, silicon nitride fibres, and boron nitride fibres.
8. A gas turbine engine as claimed in claim 1, wherein each of the plurality of circumferentially spaced axles comprises a third metal matrix composite material, the third metal matrix composite material comprising reinforcing fibres extending axially between the first ring and the second ring.
9. A gas turbine engine as claimed in claim 8, wherein the third metal matrix composite material comprises a metal matrix selected from a group consisting essentially of a steel matrix, a titanium matrix, and a titanium alloy matrix.
10. A gas turbine engine as claimed in claim 8, wherein the third metal matrix composite material comprises silicon carbide fibres, silicon nitride fibres, or boron nitride fibres.
11. A gas turbine engine as claimed in claim 1, wherein each planet gear is rotatably mounted on the carrier by a bearing selected from a group consisting essentially of a journal bearing and at least one rolling element bearing.
12. A gas turbine engine as claimed in claim 11, wherein each planet gear is rotatably mounted on the carrier by two rolling element bearings.
13. A gas turbine engine as claimed in claim 1, wherein the carrier is connected to an output shaft and the annulus gear is connected to a static structure.
14. A gas turbine engine as claimed in claim 1, wherein the carrier is connected to a static structure and the annulus gear is connected to an output shaft.
15. A gas turbine engine as claimed in claim 1, wherein the gas turbine engine comprises a propulsor, an intermediate-pressure compressor, a high-pressure compressor, a high-pressure turbine, and a low-pressure turbine; the high-pressure turbine is arranged to directly drive the high-pressure compressor the low-pressure turbine is arranged to directly drive the intermediate-pressure compressor; and the low-pressure turbine is arranged to drive the propulsor via the gearbox.
16. A gas turbine engine as claimed in claim 15, wherein the propulsor is selected from a group consisting essentially of a fan and a propeller.
17. A gas turbine engine as claimed in claim 1, wherein the gas turbine engine comprises a low-pressure turbine, a static structure, and a propulsor; the sun gear is driven by the low-pressure turbine; the annulus gear is secured to the static structure; and the carrier is arranged to drive the propulsor.
18. A gas turbine engine as claimed in claim 1, wherein the gas turbine engine comprises a low-pressure turbine, a static structure, and a propulsor; the sun gear is driven by the low-pressure turbine; the carrier is secured to the static structure; and the annulus gear is arranged to drive the propulsor.
19. A gearbox comprising: a sun gear; an annulus gear; a plurality of planet gears; and a carrier, the sun gear meshing with the planet gears and the planet gears meshing with the annulus gear; the carrier comprising a first ring, a second ring spaced axially from the first ring, and a plurality of circumferentially spaced axles extending axially between the first ring and the second ring; each planet gear being rotatably mounted on a respective one of the plurality of circumferentially spaced axles, each of the plurality of circumferentially spaced axles being arranged at a first radius; and at least one of the first ring and the second ring comprising a metal matrix composite material, the metal matrix composite material comprising a ring of reinforcing fibres, and the ring of reinforcing fibres having a second radius greater than the first radius.
20. A planet gear carrier comprising: a first ring; a second ring spaced axially from the first ring; a plurality of circumferentially spaced axles extending axially between the first ring and the second ring; and a plurality of planet gears, each planet gear being rotatably mounted on a respective one of the plurality of circumferentially spaced axles, each of the plurality of circumferentially spaced axles being arranged at a first radius; and at least one of the first ring and the second ring comprising a metal matrix composite material, the metal matrix composite material comprising a ring of reinforcing fibres, and the ring of reinforcing fibres having a second radius greater than the first radius.
Description
(1) Embodiments of the disclosure will now be described by way of example only, with reference to the Figures, in which:
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(9) With reference to
(10) The gas turbine engine 10 works in the conventional manner so that air entering the intake 12 is compressed by the fan 13 to produce two air flows: a first air flow A into the intermediate-pressure compressor 14 and a second air flow B which passes through the bypass duct 22 to provide the majority of the propulsive thrust. The intermediate-pressure compressor 14 compresses the air flow directed into it before delivering that air to the high-pressure compressor 15 where further compression takes place.
(11) The compressed air exhausted from the high-pressure compressor 15 is directed into the combustion equipment 16 where it is mixed with fuel and the mixture combusted. The resultant hot combustion products then expand through, and thereby drive the high and low-pressure turbines 17, 19 before being exhausted through the core nozzle 20 to provide additional propulsive thrust. The high-pressure turbine 17 drives the high-pressure compressor 15 by a shaft 23. The low-pressure turbine 19 drives the intermediate-pressure compressor 14 directly via shafts 26 and 27. The low-pressure turbine 19 drives the fan 13 indirectly via the shaft 26, a gearbox 28 and a shaft 38. The gearbox 28 is a planetary gearbox and comprises a sun gear 30, an annulus gear 32, a plurality of planet gears 34 and a planet gear carrier 36. The sun gear 30 meshes with the planet gears 34 and the planet gears 34 mesh with the annulus gear 32. The planet gear carrier 36 constrains the planet gears 34 to precess around the sun gear 30 in synchronicity whilst enabling each planet gear 34 to rotate about its own axis independently. The planet gear carrier 36 is coupled via the shaft 38 to the fan 13 in order to drive its rotation about the engine axis 9. The annulus gear 32 is coupled to a static structure 24. The axes of the planet gears 34 and the axis of the planet gear carrier 36 are parallel to the engine axis 9. The shaft 38 is rotatably mounted in static structure by one or more bearings, e.g. rolling element bearings, e.g. roller bearings or ball bearings.
(12) The gearbox 28 is shown more clearly in
(13)
(14) The long reinforcing fibres 50 in the metal matrix composite material ring 54A of the first ring 36A are arranged at a radius greater than the radius at which the apertures 48A are arranged. The long reinforcing fibres 50 in the metal matrix composite material ring 54B of the second ring 36B are also arranged at a radius greater than the radius at which the apertures 48B are arranged. Each of the axles 40 comprises a metal matrix composite material and each axle 40 comprises long reinforcing fibres 56 in a metal matrix material 58. The long reinforcing fibres 56 extend axially between the first ring 36A and the second ring 36B. The axes of the axles 48 and hence the axes of the apertures 48A and 488 are arranged at a first radius R.sub.1 with respect to the axis of the gearbox 28 and the axis 9 of the turbofan gas turbine engine 10. The first continuous ring 54A and the second continuous ring 54B are arranged at a second radius R.sub.2 with respect to the axis of the gearbox 28 and the axis 9 of the turbofan gas turbine engine 10 and the second radius R.sub.2 is greater than the first radius R.sub.1.
(15) The first metal matrix composite material ring 54A of the first ring 36A may be reinforced with silicon carbide fibres, silicon nitride fibres or boron nitride fibres. The first metal matrix composite material ring 54A of the first ring 36A may comprise an iron matrix, a steel matrix, a titanium matrix, a titanium alloy matrix, an aluminium matrix, an aluminium alloy matrix, a nickel matrix or a nickel alloy matrix. The second metal matrix composite material ring 54B of the second ring 36B may be reinforced with silicon carbide fibres, silicon nitride fibres or boron nitride fibres. The second metal matrix composite material ring 54B of the second ring 36B may comprise an iron matrix, a steel matrix, a titanium matrix, a titanium alloy matrix, an aluminium matrix, an aluminium alloy matrix, a nickel matrix or a nickel alloy matrix. The metal matrix composite material of the axles 40 may be reinforced with silicon carbide fibres, silicon nitride fibres or boron nitride fibres. The metal matrix composite material of the axles 40 may comprise an iron matrix, a steel matrix, a titanium matrix, a titanium alloy matrix, an aluminium matrix, an aluminium alloy matrix, a nickel matrix or a nickel alloy matrix.
(16) Each metal matrix composite material component, the first metal matrix composite material ring 54A, the second metal matrix composite material ring 54B and the axles 40 may be made by making a fibre preform and then depositing a metal matrix material on and around the fibre preform. The metal matrix may be deposited onto the reinforcing fibres using for example vapour deposition, e.g. physical vapour deposition, by thermal spraying or plasma spraying.
(17) In a first example the first metal matrix composite material ring 54A, the second metal matrix composite material ring 54B and the axles 40 comprise a titanium matrix composite with silicon carbide reinforcing fibres. The remainder of the first ring 36A and the remainder of the second ring 36B comprise unreinforced titanium. In a second example the first metal matrix composite material ring 54A, the second metal matrix composite material ring 54B and the axles 40 comprise an iron matrix composite with silicon carbide reinforcing fibres. The remainder of the first ring 36A and the remainder of the second ring 36B comprise unreinforced iron. In a third example the first metal matrix composite material ring 54A, the second metal matrix composite material ring 54B and the axles 40 comprise a steel matrix composite with silicon carbide reinforcing fibres. The remainder of the first ring 36A and the remainder of the second ring 36B comprise unreinforced steel. In each of these examples the silicon carbide fibres may be replaced with silicon nitride fibres or boron nitride fibres.
(18) The first metal matrix composite material ring 54A and the second metal matrix composite material ring 54B with long reinforcing fibres 50 have the reinforcing fibres aligned, or arranged, to carry the loads acting on the planet gear carrier 36 and produce a stiffer structure.
(19) The advantage of the present disclosure is that it enables the planet gear carder to be made as small and lightweight as is practical while providing positioning of the planet gears. The first metal matrix composite material ring and the second metal matrix composite material ring of the planet gear carder are optimised to provide a stiff lightweight reinforcement for the planet gear carder so that it is able to support the loads applied to the planet gears and planet gear bearings, which are generated by torque or centrifugally generated. A planet gear carder comprising a first metal matrix composite material ring and a second metal matrix composite material ring is also able to maintain the positions of the gears very accurately to maintain adequate gear performance in terms of controlling the tooth loading and the noise, or vibration, levels. The weight of the planet gear carder is significantly reduced. Alternatively, a planet gear carder comprising a first metal matrix composite material ring and a second metal matrix composite material ring may be designed to have increased stiffness such that smaller, more efficient teeth may be provided on the sun gear, planet gears and annulus gear.
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(22) In each of the arrangements described above the sun gear, the annulus gear, the carrier and the shaft are coaxial.
(23) In each of the arrangements described above the lubricant, e.g. oil, lubricates and cools the sun, annulus and planet gears and the bearings of the planet gears.
(24) Although the present discourse has referred to a planet gear carrier with reinforcing fibres in the axles of the planet gear carrier it is equally possible to provide a planet gear carrier with unreinforced axles.
(25) Although the present disclosure has referred to a planet gear carrier with a first metal matrix composite material ring and a second metal matrix composite material ring in the first and second rings it may be equally possible to provide only a single metal matrix composite material ring in one of the first and second rings of the planet gear carrier.
(26) Similarly it may be possible to provide more two metal matrix composite material rings in each of the first and second rings of the planet gear carrier. One of the metal matrix composite material rings in each of the first and second rings is provided at a radius greater than the radius at which the axes of the axles are arranged and the other of the metal matrix composite material rings in each of the first and second rings may be arranged at a radius greater than the radius at which the axes of the axles are arranged or at a radius less than the radius at which the axes of the axles are arranged.
(27) As described above, the gas turbine engine comprises a propulsor, an intermediate-pressure compressor, a high-pressure compressor, a high-pressure turbine and a low-pressure turbine, the high-pressure turbine is arranged to directly drive the high-pressure compressor, the low-pressure turbine is arranged to directly drive the intermediate-pressure compressor and the low-pressure turbine is arranged to drive the propulsor via a gearbox.
(28) Alternatively, the gas turbine engine comprises a propulsor, an intermediate-pressure compressor, a high-pressure compressor, a high-pressure turbine and a low-pressure turbine, the high-pressure turbine is arranged to directly drive the high-pressure compressor, the low-pressure turbine is arranged to directly drive the propulsor and the low-pressure turbine is arranged to drive the intermediate-pressure compressor via a gearbox.
(29) Alternatively, the gas turbine engine comprises a propulsor, an intermediate-pressure compressor, a high-pressure compressor, a high-pressure turbine, an intermediate-pressure turbine and a low-pressure turbine, the high-pressure turbine is arranged to directly drive the high-pressure compressor, the intermediate-pressure turbine is arranged to directly drive the intermediate-pressure compressor and the low-pressure turbine is arranged to drive the propulsor via a gearbox.
(30) Alternatively the gas turbine engine may comprise a propulsor, a high-pressure compressor, a high-pressure turbine and a low-pressure turbine, the high-pressure turbine is arranged to directly drive the high-pressure compressor and the low-pressure turbine is arranged to drive the propulsor via a gearbox.
(31) Alternatively, the gas turbine engine comprises a first propulsor, a second propulsor, an intermediate-pressure compressor, a high-pressure compressor, a high-pressure turbine, an intermediate-pressure turbine and a low-pressure turbine, the high-pressure turbine is arranged to directly drive the high-pressure compressor, the intermediate-pressure turbine is arranged to directly drive the intermediate-pressure compressor and the low-pressure turbine is arranged to drive the first propulsor and the second propulsor via a gearbox.
(32) Alternatively, the gas turbine engine comprises a first propulsor, a second propulsor, a low-pressure compressor, a high-pressure compressor, a high-pressure turbine, a low-pressure turbine and a free power turbine, the high-pressure turbine is arranged to directly drive the high-pressure compressor, the low-pressure turbine is arranged to directly drive the low-pressure compressor and the free power turbine is arranged to drive the first propulsor and the second propulsor via a gearbox.
(33) Alternatively, the gas turbine engine comprises a first propulsor, a second propulsor, a low-pressure compressor, a high-pressure compressor, a high-pressure turbine and a low-pressure turbine, the high-pressure turbine is arranged to directly drive the high-pressure compressor, the low-pressure turbine is arranged to directly drive the low-pressure compressor and the low-pressure turbine is arranged to drive the first propulsor and the second propulsor via a gearbox.
(34) The sun gear may be driven by a low-pressure turbine, the annulus gear may be secured to static structure and the carrier may be arranged to drive a propulsor.
(35) The sun gear may be driven by the low-pressure turbine, the carrier may be secured to static structure and the annulus gear may be arranged to drive a propulsor. In this arrangement each planet gear rotates about its own axis and the carrier does not rotate about the engine axis. The axes of the planet gears are parallel to the engine axis.
(36) The carrier may be driven by the low-pressure turbine, the sun gear may be secured to static structure and the annulus gear may be arranged to drive a propulsor.
(37) The sun gear may be driven by the low-pressure turbine, the carrier may be arranged to drive a first propulsor and the annulus gear may be arranged to drive a second propulsor.
(38) Although the present disclosure has been described with reference to planetary gearbox, star gearbox and differential gearbox arrangements it is equally possible for the gearbox to be arranged in a solar gearbox arrangement, e.g. the sun gear is secured to static structure and either the carrier is driven by an input drive shaft and the annulus gear drives an output drive shaft or the annulus gear is driven by an input drive shaft and the carrier drives an output drive shaft.
(39) The propulsor may be a fan or a propeller.
(40) It will be understood that the invention is not limited to the embodiments above-described and various modifications and improvements can be made without departing from the concepts described herein. Except where mutually exclusive, any of the features may be employed separately or in combination with any other features and the disclosure extends to and includes all combinations and sub-combinations of one or more features described herein.