METHOD FOR SETTING A GEAR RATIO OF A FAN DRIVE GEAR SYSTEM OF A GAS TURBINE ENGINE

In one exemplary embodiment, a gas turbine engine includes an engine centerline longitudinal axis. A fan section includes a fan with a plurality of fan blades. The fan has a low corrected fan tip speed less than 1400 ft/sec. A bypass ratio is greater than 13 and less than 20. A fan pressure ratio less than 1.38 at cruise conditions of 0.8 Mach and about 35,000 feet. A speed reduction device comprises a gear system with a gear ratio of at least 2.6 and less than or equal to 4.1. A low pressure turbine is in communication with a first shaft. A high pressure turbine is in communication a second shaft. The first shaft is in communication with the fan through the speed reduction device. The low pressure turbine includes at least three stages and no more than four stages. The high pressure turbine includes two stages.

Skip to: Description  ·  Claims  · Patent History  ·  Patent History
Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This disclosure is a continuation of U.S. application Ser. No. 15/875,656 filed Jan. 19, 2018, which is a continuation of U.S. application Ser. No. 14/705,577 filed May 6, 2015, which is a continuation in part of PCT/US2013/061115 filed on Sep. 23, 2013, which is a continuation of U.S. application Ser. No. 13/758,075 filed Feb. 4, 2013, which is now U.S. Pat. No. 8,753,065 issued on Jun. 17, 2014.

BACKGROUND

This disclosure relates to a gas turbine engine, and more particularly to a method for setting a gear ratio of a fan drive gear system of a gas turbine engine.

A gas turbine engine may include a fan section, a compressor section, a combustor section, and a turbine section. Air entering the compressor section is compressed and delivered into the combustor section where it is mixed with fuel and ignited to generate a high-speed exhaust gas flow. The high-speed exhaust gas flow expands through the turbine section to drive the compressor and the fan section. Among other variations, the compressor section can include low and high pressure compressors, and the turbine section can include low and high pressure turbines.

Typically, a high pressure turbine drives a high pressure compressor through an outer shaft to form a high spool, and a low pressure turbine drives a low pressure compressor through an inner shaft to form a low spool. The fan section may also be driven by the inner shaft. A direct drive gas turbine engine may include a fan section driven by the low spool such that a low pressure compressor, low pressure turbine, and fan section rotate at a common speed in a common direction.

A speed reduction device, which may be a fan drive gear system or other mechanism, may be utilized to drive the fan section such that the fan section may rotate at a speed different than the turbine section. This allows for an overall increase in propulsive efficiency of the engine. In such engine architectures, a shaft driven by one of the turbine sections provides an input to the speed reduction device that drives the fan section at a reduced speed such that both the turbine section and the fan section can rotate at closer to optimal speeds.

Although gas turbine engines utilizing speed change mechanisms are generally known to be capable of improved propulsive efficiency relative to conventional engines, gas turbine engine manufacturers continue to seek further improvements to engine performance including improvements to thermal, transfer and propulsive efficiencies.

SUMMARY

In one exemplary embodiment, a gas turbine engine includes an engine centerline longitudinal axis. A fan section includes a fan with a plurality of fan blades and rotatable about the engine centerline longitudinal axis. The fan has a low corrected fan tip speed less than 1400 ft/sec. The low corrected fan tip speed is an actual fan tip speed at an ambient temperature divided by [(Tram °R)/(518.7 °R)] 0.5. T represents the ambient temperature in degrees Rankine. A bypass ratio is greater than 13 and less than 20. A fan pressure ratio less than 1.48. The fan pressure ratio is measured across a fan blade alone. A speed reduction device comprises a gear system with a gear ratio of at least 2.6 and less than or equal to 4.1. There is a plurality of bearing systems. A low pressure turbine is in communication with a first shaft. A high pressure turbine is in communication a second shaft. The first shaft and second shaft are concentric and mounted via at least one of the plurality of bearing systems for rotation about the engine centerline longitudinal axis. The first shaft is in communication with the fan through the speed reduction device. The low pressure turbine includes at least three stages and no more than four stages. The high pressure turbine includes two stages. The low pressure turbine includes at least one rotor constrained by a first stress level. At least one of the plurality of fan blades of the fan is constrained by a second stress level and has a fan tip speed boundary condition. The gear ratio is configured such that in operation the fan blade does not exceed the fan tip speed boundary condition or the second stress level. The low pressure turbine rotor does not exceed the first stress level.

In a further embodiment of any of the above, the low pressure turbine includes four stages.

In a further embodiment of any of the above, the gear system is a star gear system with a ring gear and a sun gear. The gear ratio is determined by measuring a diameter of the ring gear and dividing that diameter by the diameter of the sun gear.

In a further embodiment of any of the above, the fan pressure ratio is less than 1.38.

In a further embodiment of any of the above, the fan pressure ratio is less than 1.38.

In another exemplary embodiment, a gas turbine engine includes an engine centerline longitudinal axis. A fan section includes a fan with a plurality of fan blades and rotatable about the engine centerline longitudinal axis. The fan has a low corrected fan tip speed less than 1400 ft/sec. The low corrected fan tip speed is an actual fan tip speed at an ambient temperature divided by [(Tram °R)/(518.7 °R)]0.5. T represents the ambient temperature in degrees Rankine. A bypass ratio is greater than 11.0 and less than 22.0. A fan pressure ratio is less than 1.38. The fan pressure ratio is measured across a fan blade alone. A speed reduction device comprises a gear system. There is a plurality of bearing systems. A low pressure turbine is in communication with a first shaft. A high pressure turbine is in communication with a second shaft. The first shaft and second shaft are concentric and mounted via at least one of the plurality of bearing systems for rotation about the engine centerline longitudinal axis. The first shaft is in communication with the fan through the speed reduction device. The high pressure turbine includes two stages. The low pressure turbine includes at least one rotor constrained by a first stress level. At least one of the plurality of fan blades of the fan is constrained by a second stress level and has a fan tip speed boundary condition. The gear system is configured such that in operation the fan blade does not exceed the fan tip speed boundary condition or the second stress level. The low pressure turbine rotor does not exceed the first stress level.

In a further embodiment of any of the above, the low pressure turbine includes five stages.

In a further embodiment of any of the above, a low pressure compressor including three stages. The low pressure turbine drives the low pressure compressor.

In a further embodiment of any of the above, the low pressure turbine includes at least three stages and no more than four stages.

In a further embodiment of any of the above, the speed reduction device includes a gear ratio less than or equal to 4.1.

In a further embodiment of any of the above, the gear ratio is greater than or equal to 2.6.

In a further embodiment of any of the above, the low pressure turbine includes four stages.

In a further embodiment of any of the above, a mid-turbine frame is arranged between the high pressure turbine and the low pressure turbine. The mid-turbine frame supports at least one bearing system.

In a further embodiment of any of the above, the mid-turbine frame includes one or more airfoils that extend in a flow path.

In a further embodiment of any of the above, a low pressure compressor including three stages. The low pressure turbine drives the low pressure compressor.

In a further embodiment of any of the above, a high pressure compressor includes eight stages. The high pressure turbine drives the high pressure compressor.

In a further embodiment of any of the above, the star gear system further comprising five intermediate gears.

In a further embodiment of any of the above, the gear system is a star gear system with a ring gear, a sun gear, and a star gear ratio. The star gear ratio is determined by measuring a diameter of the ring gear and dividing that diameter by the diameter of the sun gear.

In a further embodiment of any of the above, a mid-turbine frame is arranged between the high pressure turbine and the low pressure turbine. The mid-turbine frame supports at least one bearing system and includes one or more airfoils.

In another exemplary embodiment, a gas turbine engine includes an engine centerline longitudinal axis. A fan section includes a fan with a plurality of fan blades and rotatable about the engine centerline longitudinal axis and has a low corrected fan tip speed less than 1400 ft/sec. The low corrected fan tip speed is an actual fan tip speed at an ambient temperature divided by [(Tram °R)/(518.7 °R)]0.5. T represents the ambient temperature in degrees Rankine. A bypass ratio of greater than 11.0. A speed reduction device comprising a gear system. There is a plurality of bearing systems. A low pressure turbine is in communication with a first shaft and includes a pressure ratio greater than about 5:1. The low pressure turbine includes an inlet that has an inlet pressure and an outlet having an outlet pressure. The pressure ratio of the low pressure turbine is a ratio of the inlet pressure to the outlet pressure. A high pressure turbine in communication with a second shaft. The first shaft and second shaft are concentric and mounted via at least one of the plurality of bearing systems for rotation about the engine centerline longitudinal axis. The first shaft is in communication with the fan through the speed reduction device. The low pressure turbine includes at least three stages and no more than four stages. The low pressure turbine includes at least one rotor constrained by a first stress level. At least one of the plurality of fan blades of the fan is constrained by a second stress level and has a fan tip speed boundary condition. The gear system is configured such that in operation the fan blade does not exceed the fan tip speed boundary condition or the second stress level. The low pressure turbine rotor does not exceed the first stress level.

In a further embodiment of any of the above, the high pressure turbine includes two stages.

In a further embodiment of any of the above, the low pressure turbine includes three stages.

In a further embodiment of any of the above, the gear system has a gear ratio of less than or equal to 4.1.

In a further embodiment of any of the above, the gear reduction ratio is at least 2.6.

In a further embodiment of any of the above, the gear system is a star gear system with a ring gear and a sun gear. The gear ratio is determined by measuring a diameter of the ring gear and dividing that diameter by the diameter of the sun gear.

In a further embodiment of any of the above, the low pressure turbine includes four stages.

In another exemplary embodiment, a gas turbine engine includes an engine centerline longitudinal axis. A fan section includes a fan with a plurality of fan blades and rotatable about the engine centerline longitudinal axis and has a low corrected fan tip speed less than 1400 ft/sec. The low corrected fan tip speed is an actual fan tip speed at an ambient temperature divided by [(Tram °R)/(518.7 °R)]0.5. T represents the ambient temperature in degrees Rankine. A bypass ratio is greater than 11 and less than 22. A speed reduction device comprises a gear system with a gear ratio. A plurality of bearing systems. A low pressure turbine is in communication with a first shaft and a high pressure turbine in communication with a second shaft. The first shaft and second shaft are concentric and mounted via at least one of the plurality of bearing systems for rotation about the engine centerline longitudinal axis. The first shaft is in communication with the fan through the speed reduction device. The low pressure turbine includes four stages. The low pressure turbine includes at least one rotor constrained by a first stress level. At least one of the plurality of fan blades of the fan is constrained by a second stress level and has a fan tip speed boundary condition. The gear ratio is configured such that in operation the fan blade does not exceed the fan tip speed boundary condition or the second stress level. The low pressure turbine rotor does not exceed the first stress level.

In a further embodiment of any of the above, the high pressure turbine includes two stages.

In a further embodiment of any of the above, the gear reduction ratio is at least 2.6 and less than or equal to 4.1.

In a further embodiment of any of the above, the low pressure turbine has a pressure ratio greater than 5:1. The low pressure turbine includes an inlet that has an inlet pressure and an outlet that has an outlet pressure. The pressure ratio of the low pressure turbine is a ratio of the inlet pressure to the outlet pressure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a schematic, cross-sectional view of an example gas turbine engine.

FIG. 2 illustrates a schematic view of one configuration of a low speed spool that can be incorporated into a gas turbine engine.

FIG. 3 illustrates a fan drive gear system that can be incorporated into a gas turbine engine.

FIG. 4 shows another embodiment.

FIG. 5 shows yet another embodiment.

 DETAILED DESCRIPTION

FIG. 1 schematically illustrates a gas turbine engine 20. The exemplary gas turbine engine 20 is a two-spool turbofan engine that generally incorporates a fan section 22, a compressor section 24, a combustor section 26 and a turbine section 28. Alternative engines might include an augmentor section (not shown) among other systems or features. The fan section 22 drives air along a bypass flow path B, while the compressor section 24 drives air along a core flow path C for compression and communication into the combustor section 26. The hot combustion gases generated in the combustor section 26 are expanded through the turbine section 28. Although depicted as a two-spool turbofan gas turbine engine in the disclosed non-limiting embodiment, it should be understood that the concepts described herein are not limited to two-spool turbofan engines and these teachings could extend to other types of engines, including but not limited to, three-spool engine architectures.

The exemplary gas turbine engine 20 generally includes a low speed spool 30 and a high speed spool 32 mounted for rotation about an engine centerline longitudinal axis A. The low speed spool 30 and the high speed spool 32 may be mounted relative to an engine static structure 33 via several bearing systems 31. It should be understood that other bearing systems 31 may alternatively or additionally be provided, and the location of bearing systems 31 may be varied as appropriate to the application.

The low speed spool 30 generally includes an inner shaft 34 that interconnects a fan 36, a low pressure compressor 38 and a low pressure turbine 39. The inner shaft 34 can be connected to the fan 36 through a speed change mechanism, which in exemplary gas turbine engine 20 is illustrated as a geared architecture 45, such as a fan drive gear system 50 (see FIGS. 2 and 3). The speed change mechanism drives the fan 36 at a lower speed than the low speed spool 30. The high speed spool 32 includes an outer shaft 35 that interconnects a high pressure compressor 37 and a high pressure turbine 40. In this embodiment, the inner shaft 34 and the outer shaft 35 are supported at various axial locations by bearing systems 31 positioned within the engine static structure 33.

A combustor 42 is arranged in exemplary gas turbine 20 between the high pressure compressor 37 and the high pressure turbine 40. A mid-turbine frame 44 may be arranged generally between the high pressure turbine 40 and the low pressure turbine 39. The mid-turbine frame 44 can support one or more bearing systems 31 of the turbine section 28. The mid-turbine frame 44 may include one or more airfoils 46 that extend within the core flow path C. It will be appreciated that each of the positions of the fan section 22, compressor section 24, combustor section 26, turbine section 28, and fan drive gear system 50 may be varied. For example, gear system 50 may be located aft of combustor section 26 or even aft of turbine section 28, and fan section 22 may be positioned forward or aft of the location of gear system 50.

The inner shaft 34 and the outer shaft 35 are concentric and rotate via the bearing systems 31 about the engine centerline longitudinal axis A, which is co-linear with their longitudinal axes. The core airflow is compressed by the low pressure compressor 38 and the high pressure compressor 37, is mixed with fuel and burned in the combustor 42, and is then expanded over the high pressure turbine 40 and the low pressure turbine 39. The high pressure turbine 40 and the low pressure turbine 39 rotationally drive the respective high speed spool 32 and the low speed spool 30 in response to the expansion.

In a non-limiting embodiment, the gas turbine engine 20 is a high-bypass geared aircraft engine. In a further example, the gas turbine engine 20 bypass ratio is greater than about six (6:1). The geared architecture 45 can include an epicyclic gear train, such as a planetary gear system, a star gear system, or other gear system. The geared architecture 45 enables operation of the low speed spool 30 at higher speeds, which can enable an increase in the operational efficiency of the low pressure compressor 38 and low pressure turbine 39, and render increased pressure in a fewer number of stages.

The pressure ratio of the low pressure turbine 39 can be pressure measured prior to the inlet of the low pressure turbine 39 as related to the pressure at the outlet of the low pressure turbine 39 and prior to an exhaust nozzle of the gas turbine engine 20. In one non-limiting embodiment, the bypass ratio of the gas turbine engine 20 is greater than about ten (10:1), the fan diameter is significantly larger than that of the low pressure compressor 38, and the low pressure turbine 39 has a pressure ratio that is greater than about five (5:1). In another non-limiting embodiment, the bypass ratio is greater than 11 and less than 22, or greater than 13 and less than 20. It should be understood, however, that the above parameters are only exemplary of a geared architecture engine or other engine using a speed change mechanism, and that the present disclosure is applicable to other gas turbine engines, including direct drive turbofans. In one non-limiting embodiment, the low pressure turbine 39 includes at least one stage and no more than eight stages, or at least three stages and no more than six stages. In another non-limiting embodiment, the low pressure turbine 39 includes at least three stages and no more than four stages.

In this embodiment of the exemplary gas turbine engine 20, a significant amount of thrust is provided by the bypass flow path B due to the high bypass ratio. The fan section 22 of the gas turbine engine 20 is designed for a particular flight condition—typically cruise at about 0.8 Mach and about 35,000 feet. This flight condition, with the gas turbine engine 20 at its best fuel consumption, is also known as bucket cruise Thrust Specific Fuel Consumption (TSFC). TSFC is an industry standard parameter of fuel consumption per unit of thrust.

Fan Pressure Ratio is the pressure ratio across a blade of the fan section 22 without the use of a Fan Exit Guide Vane system. The low Fan Pressure Ratio according to one non-limiting embodiment of the example gas turbine engine 20 is less than 1.45. In another non-limiting embodiment of the example gas turbine engine 20, the Fan Pressure Ratio is less than 1.38 and greater than 1.25. In another non-limiting embodiment, the fan pressure ratio is less than 1.48. In another non-limiting embodiment, the fan pressure ratio is less than 1.52. In another non-limiting embodiment, the fan pressure ratio is less than 1.7. Low Corrected Fan Tip Speed is the actual fan tip speed divided by an industry standard temperature correction of [(Tram °R)/(518.7 °R)]0.5, where T represents the ambient temperature in degrees Rankine. The Low Corrected Fan Tip Speed according to one non-limiting embodiment of the example gas turbine engine 20 is less than about 1150 fps (351 m/s). The Low Corrected Fan Tip Speed according to another non-limiting embodiment of the example gas turbine engine 20 is less than about 1400 fps (427 m/s). The Low Corrected Fan Tip Speed according to another non-limiting embodiment of the example gas turbine engine 20 is greater than about 1000 fps (305 m/s).

FIG. 2 schematically illustrates the low speed spool 30 of the gas turbine engine 20. The low speed spool 30 includes the fan 36, the low pressure compressor 38, and the low pressure turbine 39. The inner shaft 34 interconnects the fan 36, the low pressure compressor 38, and the low pressure turbine 39. The inner shaft 34 is connected to the fan 36 through the fan drive gear system 50. In this embodiment, the fan drive gear system 50 provides for counter-rotation of the low pressure turbine 39 and the fan 36. For example, the fan 36 rotates in a first direction D1, whereas the low pressure turbine 39 rotates in a second direction D2 that is opposite of the first direction D1.

FIG. 3 illustrates one example embodiment of the fan drive gear system 50 incorporated into the gas turbine engine 20 to provide for counter-rotation of the fan 36 and the low pressure turbine 39. In this embodiment, the fan drive gear system 50 includes a star gear system with a sun gear 52, a ring gear 54 disposed about the sun gear 52, and a plurality of star gears 56 having journal bearings 57 positioned between the sun gear 52 and the ring gear 54. A fixed carrier 58 carries and is attached to each of the star gears 56. In this embodiment, the fixed carrier 58 does not rotate and is connected to a grounded structure 55 of the gas turbine engine 20.

The sun gear 52 receives an input from the low pressure turbine 39 (see FIG. 2) and rotates in the first direction D1 thereby turning the plurality of star gears 56 in a second direction D2 that is opposite of the first direction D1. Movement of the plurality of star gears 56 is transmitted to the ring gear 54 which rotates in the second direction D2 opposite from the first direction D1 of the sun gear 52. The ring gear 54 is connected to the fan 36 for rotating the fan 36 (see FIG. 2) in the second direction D2.

A star system gear ratio of the fan drive gear system 50 is determined by measuring a diameter of the ring gear 54 and dividing that diameter by a diameter of the sun gear 52. In one embodiment, the star system gear ratio of the geared architecture 45 is between 1.5 and 4.1. In another embodiment, the system gear ratio of the fan drive gear system 50 is between 2.6 and 4.1. When the star system gear ratio is below 1.5, the sun gear 52 is relatively much larger than the star gears 56. This size differential reduces the load the star gears 56 are capable of carrying because of the reduction in size of the star gear journal bearings 57. When the star system gear ratio is above 4.1, the sun gear 52 may be much smaller than the star gears 56. This size differential increases the size of the star gear 56 journal bearings 57 but reduces the load the sun gear 52 is capable of carrying because of its reduced size and number of teeth. Alternatively, roller bearings could be used in place of journal bearings 57.

Improving performance of the gas turbine engine 20 begins by determining fan tip speed boundary conditions for at least one fan blade of the fan 36 to define the speed of the tip of the fan blade. The maximum fan diameter is determined based on the projected fuel burn derived from balancing engine efficiency, mass of air through the bypass flow path B, and engine weight increase due to the size of the fan blades.

Boundary conditions are then determined for the rotor of each stage of the low pressure turbine 39 to define the speed of the rotor tip and to define the size of the rotor and the number of stages in the low pressure turbine 39 based on the efficiency of low pressure turbine 39 and the low pressure compressor 38.

Constraints regarding stress levels in the rotor and the fan blade are utilized to determine if the rotary speed of the fan 36 and the low pressure turbine 39 will meet a desired number of operating life cycles. If the stress levels in the rotor or the fan blade are too high, the gear ratio of the fan drive gear system 50 can be lowered and the number of stages of the low pressure turbine 39 or annular area of the low pressure turbine 39 can be increased.

FIG. 4 shows an embodiment 100, wherein there is a fan drive turbine 108 driving a shaft 106 to in turn drive a fan rotor 102. A gear reduction 104 may be positioned between the fan drive turbine 108 and the fan rotor 102. This gear reduction 104 may be structured and operate like the geared architecture 45 disclosed above. A compressor rotor 110 is driven by an intermediate pressure turbine 112, and a second stage compressor rotor 114 is driven by a turbine rotor 116. A combustion section 118 is positioned intermediate the compressor rotor 114 and the turbine section 116.

FIG. 5 shows yet another embodiment 200 wherein a fan rotor 202 and a first stage compressor 204 rotate at a common speed. The gear reduction 206 (which may be structured as the geared architecture 45 disclosed above) is intermediate the compressor rotor 204 and a shaft 208 which is driven by a low pressure turbine section.

Although the different non-limiting embodiments are illustrated as having specific components, the embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments.

It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should also be understood that although a particular component arrangement is disclosed and illustrated in these exemplary embodiments, other arrangements could also benefit from the teachings of this disclosure.

The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claim should be studied to determine the true scope and content of this disclosure.

Claims

1. A gas turbine engine comprising:

an engine centerline longitudinal axis;
a fan section including a fan with a plurality of fan blades wherein the fan section drives air along a bypass flow path in a bypass duct and the fan rotates about the engine centerline longitudinal axis;
a low corrected fan tip speed less than 1400 ft/sec, wherein the low corrected fan tip speed is an actual fan tip speed at an ambient temperature divided by [(Tram °R)/(518.7 °R)]0.5, where T represents the ambient temperature in degrees Rankine;
a fan pressure ratio less than 1.38 at cruise conditions of 0.8 Mach and about 35,000 feet, wherein the fan pressure ratio is measured across a fan blade alone;
a speed reduction device comprising an epicyclic gear system having five intermediate gears and a gear ratio of at least 2.6 and less than or equal to 4.1;
a plurality of bearing systems;
a low pressure turbine in communication with a first shaft;
a high pressure turbine in communication a second shaft; and
a mid-turbine frame arranged between the high pressure turbine and the low pressure turbine, wherein the mid-turbine frame supports at least one bearing system and one or more airfoils that extend in a flow path; and
wherein the first shaft and second shaft are concentric and mounted via at least one of the plurality of bearing systems for rotation about the engine centerline longitudinal axis, and the first shaft is in communication with the fan through the speed reduction device;
wherein the low pressure turbine includes at least three stages and no more than four stages;
wherein the high pressure turbine includes two stages; and
wherein the low pressure turbine includes at least one rotor constrained by a first stress level, at least one of the plurality of fan blades of the fan constrained by a second stress level and having a fan tip speed boundary condition, and the gear ratio is configured such that in operation the fan blade does not exceed the fan tip speed boundary condition or the second stress level, and the low pressure turbine rotor does not exceed the first stress level.

2. The gas turbine engine of claim 1, wherein the low pressure turbine includes four stages.

3. The gas turbine engine of claim 2, wherein the gear system is a star gear system with a ring gear, and a sun gear, wherein the gear ratio is determined by measuring a diameter of the ring gear and dividing that diameter by the diameter of the sun gear.

4. The gas turbine engine of claim 2, a bypass ratio greater than 11.0 and less than 22.0 at cruise conditions of 0.8 Mach and about 35,000 feet.

5. The gas turbine engine of claim 2, a bypass ratio greater than 13 and less than 20 at cruise conditions of 0.8 Mach and about 35,000 feet.

6. A gas turbine engine comprising:

an engine centerline longitudinal axis;
a fan section including a fan with a plurality of fan blades wherein the fan section drives air along a bypass flow path in a bypass duct and the fan rotates about the engine centerline longitudinal axis;
a low corrected fan tip speed less than 1400 ft/sec, wherein the low corrected fan tip speed is an actual fan tip speed at an ambient temperature divided by [(Tram °R)/(518.7 °R)]0.5, where T represents the ambient temperature in degrees Rankine;
a fan pressure ratio less than 1.38 at cruise conditions of 0.8 Mach and about 35,000 feet, wherein the fan pressure ratio is measured across a fan blade alone;
a speed reduction device comprising an epicyclic gear system having five intermediate gears;
a plurality of bearing systems;
a low pressure turbine in communication with a first shaft;
a high pressure turbine in communication with a second shaft; and
a mid-turbine frame arranged between the high pressure turbine and the low pressure turbine, wherein the mid-turbine frame supports at least one bearing system and one or more airfoils that extend in a flow path; and
wherein the first shaft and second shaft are concentric and mounted via at least one of the plurality of bearing systems for rotation about the engine centerline longitudinal axis, and the first shaft is in communication with the fan through the speed reduction device;
wherein the high pressure turbine includes two stages; and
wherein the low pressure turbine includes at least one rotor constrained by a first stress level, at least one of the plurality of fan blades of the fan constrained by a second stress level and having a fan tip speed boundary condition, and the gear system is configured such that in operation the fan blade does not exceed the fan tip speed boundary condition or the second stress level, and the low pressure turbine rotor does not exceed the first stress level.

7. The gas turbine engine of claim 6, wherein the low pressure turbine includes five stages.

8. The gas turbine engine of claim 6, further comprising a low pressure compressor including three stages, wherein the low pressure turbine drives the low pressure compressor.

9. The gas turbine engine of claim 6, wherein the low pressure turbine includes at least three stages and no more than four stages.

10. The gas turbine engine of claim 6, wherein the speed reduction device includes a gear ratio less than or equal to 4.1.

11. The gas turbine engine of claim 10, wherein the gear ratio is greater than or equal to 2.6.

12. The gas turbine engine of claim 9, wherein the low pressure turbine includes four stages.

13. The gas turbine engine of claim 12, a bypass ratio greater than 11.0 and less than 22.0.

14. The gas turbine engine of claim 13, wherein the bypass ratio is at cruise conditions of 0.8 Mach and about 35,000 feet.

15. The gas turbine engine of claim 12, further comprising a low pressure compressor including three stages, wherein the low pressure turbine drives the low pressure compressor.

16. The gas turbine engine of claim 15, further comprising a high pressure compressor including eight stages, wherein the high pressure turbine drives the high pressure compressor.

17. The gas turbine engine of claim 15, wherein the gear system is a star gear system with a ring gear, a sun gear, and a star gear ratio, and the star gear ratio is determined by measuring a diameter of the ring gear and dividing that diameter by the diameter of the sun gear.

18. The gas turbine engine of claim 17, wherein the gear system includes a carrier supporting the intermediate gears and fixed from rotation relative to a static structure of the gas turbine engine.

19. The gas turbine engine of claim 6, a bypass ratio greater than 13 and less than 20 at cruise conditions of 0.8 Mach and about 35,000 feet.

20. A gas turbine engine comprising:

an engine centerline longitudinal axis;
a fan section including a fan with a plurality of fan blades wherein the fan section drives air along a bypass flow path in a bypass duct and the fan rotates about the engine centerline longitudinal axis;
a low corrected fan tip speed less than 1400 ft/sec, and the low corrected fan tip speed is an actual fan tip speed at an ambient temperature divided by [(Tram °R)/(518.7 °R)]0.5, where T represents the ambient temperature in degrees Rankine;
a bypass ratio of greater than 11.0 and less than 22 at cruise conditions of 0.8 Mach and about 35,000 feet;
a fan pressure ratio less than 1.38 and greater than 1.25 at cruise conditions of 0.8 Mach and about 35,000 feet, wherein the fan pressure ratio is measured across a fan blade alone;
a speed reduction device comprising an epicyclic gear system having five intermediate gears;
a plurality of bearing systems;
a low pressure turbine in communication with a first shaft and includes a pressure ratio greater than about 5:1, the low pressure turbine includes an inlet having an inlet pressure, and an outlet having an outlet pressure, and the pressure ratio of the low pressure turbine is a ratio of the inlet pressure to the outlet pressure;
a high pressure turbine in communication with a second shaft; and
a mid-turbine frame arranged between the high pressure turbine and the low pressure turbine, wherein the mid-turbine frame supports at least one bearing system and one or more airfoils that extend in a flow path; and
wherein the first shaft and second shaft are concentric and mounted via at least one of the plurality of bearing systems for rotation about the engine centerline longitudinal axis, and the first shaft is in communication with the fan through the speed reduction device;
wherein the low pressure turbine includes at least three stages and no more than four stages; and
wherein the low pressure turbine includes at least one rotor constrained by a first stress level, at least one of the plurality of fan blades of the fan constrained by a second stress level and having a fan tip speed boundary condition, and the gear system is configured such that in operation the fan blade does not exceed the fan tip speed boundary condition or the second stress level, and the low pressure turbine rotor does not exceed the first stress level.

21. The gas turbine engine of claim 20, wherein the high pressure turbine includes two stages.

22. The gas turbine engine of claim 21, wherein the low pressure turbine includes three stages.

23. The gas turbine engine of claim 21, wherein the gear system has a gear ratio of less than or equal to 4.1.

24. The gas turbine engine of claim 23, wherein the gear reduction ratio is at least 2.6.

25. The gas turbine engine of claim 24, wherein the gear system is a star gear system with a ring gear, and a sun gear, wherein the gear ratio is determined by measuring a diameter of the ring gear and dividing that diameter by the diameter of the sun gear.

26. The gas turbine engine of claim 24, wherein the low pressure turbine includes four stages.

27. A gas turbine engine comprising:

an engine centerline longitudinal axis;
a fan section including a fan with a plurality of fan blades wherein the fan section drives air along a bypass flow path in a bypass duct and the fan rotates about the engine centerline longitudinal axis;
a low corrected fan tip speed less than 1400 ft/sec, wherein the low corrected fan tip speed is an actual fan tip speed at an ambient temperature divided by [(Tram °R)/(518.7 °R)]0.5, where T represents the ambient temperature in degrees Rankine;
a fan pressure ratio less than 1.38 and greater than 1.25 at cruise conditions of 0.8 Mach and about 35,000 feet, wherein the fan pressure ratio is measured across a fan blade alone;
a speed reduction device comprising an epicyclic gear system having five intermediate gears and a gear ratio of at least 2.6 and less than or equal to 4.1;
a plurality of bearing systems;
a low pressure turbine in communication with a first shaft;
a high pressure turbine in communication with a second shaft;
a mid-turbine frame arranged between the high pressure turbine and the low pressure turbine, wherein the mid-turbine frame supports at least one bearing system and one or more airfoils that extend in a flow path; and
wherein the first shaft and second shaft are concentric and mounted via at least one of the plurality of bearing systems for rotation about the engine centerline longitudinal axis, and the first shaft is in communication with the fan through the speed reduction device;
wherein the low pressure turbine includes four stages; and
wherein the low pressure turbine includes at least one rotor constrained by a first stress level, at least one of the plurality of fan blades of the fan constrained by a second stress level and having a fan tip speed boundary condition, and the gear ratio is configured such that in operation the fan blade does not exceed the fan tip speed boundary condition or the second stress level, and the low pressure turbine rotor does not exceed the first stress level.

28. The gas turbine engine of claim 27, wherein the high pressure turbine includes two stages.

29. The gas turbine engine of claim 27, a bypass ratio greater than 11 and less than 22 at cruise conditions of 0.8 Mach and about 35,000 feet.

30. The gas turbine engine of claim 29, wherein the low pressure turbine has a pressure ratio greater than 5:1, the low pressure turbine includes an inlet having an inlet pressure, and an outlet having an outlet pressure, and the pressure ratio of the low pressure turbine is a ratio of the inlet pressure to the outlet pressure.

Patent History
Publication number: 20210215101
Type: Application
Filed: Mar 30, 2021
Publication Date: Jul 15, 2021
Inventors: William G. Sheridan (Southington, CT), Karl L. Hasel (Manchester, CT)
Application Number: 17/217,754
Classifications
International Classification: F02C 7/32 (20060101); F02C 7/00 (20060101); F02C 7/36 (20060101); F02C 3/04 (20060101); F02C 3/06 (20060101); F02C 3/113 (20060101); F16H 1/36 (20060101); F02C 3/107 (20060101); F16H 1/28 (20060101);