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Wings:
Rolls-Royce revs up world's most powerful aerospace gearbox

Rolls-Royce Power Gearbox [All images courtesy: Rolls-Royce plc]

 

 

UK-based Rolls-Royce has run the world's most powerful aerospace gearbox for the first time, marking a significant step in the development of its new UltraFan engine design.

The maiden run of the Rolls-Royce Power Gearbox (PGB) at the company's facility in Dahlewitz, Germany, marks the start of a series of tests that will see the gearbox reach up to 100,000 hp. That's the equivalent of more than 100 Formula 1 cars.

"We launched the UltraFan design in 2014, and now we are putting our new infrastructure to work to turn it into reality," said Mike Whitehead, the company's chief engineer and head of its Programme UltraFan Technologies, Civil Aerospace.

UltraFan will utilize the company's new advanced, geared core architecture, which relies on a broader application of innovative high-temperature materials to push the core overall pressure ratio to more than 70:1. Lightweighting is also a design priority.

The power gearbox is a vital component of the UltraFan design. It enables the engine design to offer efficient power over a wide range of take-off thrusts.

The first run took place on Rolls-Royce's Attitude Rig, which allows engineers to simulate the effects of the gearbox being on the wing of an aircraft that is climbing after take-off, coming in to land, or banking while in flight. The initial run confirmed rig dynamics and oil system functionality at low pressures and speeds.

More advanced testing will take place during the rest of the year to provide additional data on low-power high-speed combinations at various pitch and roll angles and at different simulated altitudes. High-power testing will take place next year on the PGB Power Rig where the gearbox will reach full power.

UltraFan, available from 2025, will offer a 25 percent fuel efficiency improvement over the first generation of the Rolls-Royce Trent engine. It will feature:

• A new engine core architecture -- to deliver maximum fuel burn efficiency and low emissions;
• A CTi Fan System -- carbon/titanium fan blades and a composite casing to reduce weight;
• Advanced ceramic matrix composites -- heat-resistant components that operate more effectively by requiring less cooling air; and
• A geared design that will deliver efficient power for the high-thrust, high-bypass ratio engines of the future.

Rolls-Royce is working in partnership with Liebherr-Aerospace, through their Aerospace Transmission Technologies joint venture, to develop manufacturing capability and capacity for the new Power Gearbox. Rolls-Royce leads the design definition and design integration of the Power Gearbox, as well as testing activities.

Source: Rolls-Royce

Published November 2016

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