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ANTLE – an Integration of European &National Research Programmes
AAERODAYS 20 June 2006
Nick Peacock Programme ExecutiveRolls-Royce plc
2Engine ACARE* environmental targets for 2020
Reduce fuel consumption and CO2emissions by 20%
Targets are for new engines and whole industry relative to 2000
Reduce NOXemissions by 80%
Reduce perceived external noise by 18 dB Cumulative
* Advisory Council for Aerospace Research in Europe
3ANTLE – link to European research strategy towards ACARE goals
1990’s engineDatum fuel burn
CLEAN-20% CO2
partial demonstration-80% NOX
ANTLE-12% CO2-60% NOX
VITALPropulsive efficiency
Conventional fanGeared fanContra fan
NEWACThermal efficiency
IntercooledIntercooled & recuperated
Active Core
Combined-20% CO2
EEFAE Programme
4EEFAE - ANTLE - proving technology for 2008
EEFAE Programme2 vehicles (ANTLE & CLEAN)19 partners€101M EU FP5 Programme
ANTLE“Affordable Near Term Low Emissions”Target 12% reduction in CO2 emissions and 60% reduction in NOx by 2008Engine assembly complete January 2005First start of engine 9th March 2005Test programme scheduled to complete May 2005Supported by EU, DTI & Spanish Govt.
EEFAEEEFAE
5
ANTLE Vehicle OverviewTrent 500 baseline engine with new technologies incorporated
Combustor• Lean burn
• Staged combustor
Combustor• Lean burn
• Staged combustor
Controls• Distributed systems
Controls• Distributed systems
HP compressor• 5 stages
• Blisks
HP compressor• 5 stages
• Blisks
Whole engine• Increased temperatures
and pressures
Whole engine• Increased temperatures
and pressures
Oil system• Oil pump
• Air riding carbon seals• Brush seals
Oil system• Oil pump
• Air riding carbon seals• Brush seals
Accessory gearbox• Bearings
• Seals
Accessory gearbox• Bearings
• SealsIP turbine• Cooled
• Variable capacity
IP turbine• Cooled
• Variable capacity
LP turbine• 4 stages
• Novel construction
LP turbine• 4 stages
• Novel construction
HP turbine• Reduced blade numbers• Increased temperatures
•Contra-rotating
HP turbine• Reduced blade numbers• Increased temperatures
•Contra-rotating
ANTLE = Advanced Near-Term
Low Emissions
EU, UK govt. & Spanish govt. funded
6
ANTLE HPC Technologies
New Casing Concept for reduced parts count, weight and cost.
Improved control of tip clearance and ovality
Improved Abradables
Gamma TiAl Stage 5 Blade
RR1000 Stage 5 Disc with Integral Cone & Minidisc
3D Cantilevered Vanes
RR1000/RR1000 IW joint
Blisked Mid-stage Rotors
5 Stages and ~5% less aerofoils than T500
Burn Resistant Ti Stage 1 Blade
Pressure Ratio 5.6 (c.f. 4.3 T500)
Casing Treatment Stages 1 & 2
Advanced 3D Aerodynamics
Advanced Bleed Slot Geometry
7HP compressor
5 Stage highly loaded HPCCantilevered stators with3D AerodynamicsNovel materials & Manufacturing processes(blisks, inertia welding)
Reduced parts countHigher rotational speed
Advanced blade materials
Reduced blade & disk massHigher rotational speed capability
8ANTLE lean-burn premixed combustor
Premixed flame does not pass through stochiometric mixture, avoiding peak NOxproduction.
Direct injection, lean-burn single annular combustor
Staged injector
40% CAEP/2 NOx
9HP turbine
Shroudless HP turbine with novel tip clearance control system
Reduced Blade & NGV number
Contra-Rotating HP Spool
Advanced cooling via new aerofoil manufacturing methods
10IP turbine
IP turbine supplied by AVIO
Variable capacity cooled IP turbine
Electrically actuated VNGVs(actuation supplied by Goodrich)
11LP turbine
LP turbine supplied by ITP
4 stages / reduced parts count
Novel construction
LP turbine rear frame
Novel fabricated structure supplied by Volvo Aero
12T&S Technology
Hispano-Suiza
AGB mods, lightweight ADS
Techspace Aero
FBH Air riding carbon seals
HP Telemetry Brush Seals
IGB HTO mods, lightweight
location bearing
HP/IP Buffer Seals, HTO mods,
lightweight roller bearing
HPT CRIC Brush Seal
No major issues
13Blisks
Demonstrated bliskmilling of 3D viscous aerofoils in different Ti materials
Demonstrated instrumentation of a multi-stage bliskeddrum
HPC intermediate rotor with two stages of Inco blisk
Application of blisksrequires
Repair capability Reduction in manufacturing costs
– Especially for use of Ni
14RR1000 Inertia Welded Stage 5 and Cone
DemonstratedManufacture of RR1000 stage 5 & rear conesInertia welding of HPC stage 5 & rear cone
Established optimised PWHT for RR1000
Read across to Trent 1000
RR1000 Rear Cone Forging
Finished Stage 5 & Rear Cone
15EEFAE - ANTLE - proving technology for 2008
16ANTLE being moved into INTA testbed
17
Air Systems Overview
All air system experiments completed; system behaviour was as expected taking into account the low engine conditions
A significant amount of good quality air system measurements were taken
Air system measurements did not detect any deterioration of brush seals throughout the test
18
Main Combustion Findings
Light around achieved readily
Stable engine control achieved with T30-FAR fuel staging strategy
Emissions analysis shows a good match to the rig data
Good match on NOx and smoke
19
Controls SummaryVECS
Enabled flexibility of software, no issuesDistributed controls
Performed well throughout testElectric Actuation
Demonstrated functionallyStaged Combustion
Performed as expectedHigh Energy Ignition Systems
Unison system operated faultlessly
20
Overall Results Summary - Steady state: max conditions achieved
HP Turbine rotor inlet temperature (T41) circa 1800K HP Compressor pressure ratio 5.88 cf 5.6 TOC des.LP shaft speed 2450 rpm (63%) IP shaft speed 7548 rpm (83%)HP shaft speed 14475 rpm (99%)
IP turbineVNGV closed capacity significantly greater than expectation ~ +15 to 17%Fully opening VNGVs increased capacity by ~ 7% (vs ~21% expectation)
21
Overall Summary
Generally achieved objectives
A number of technology issues need to be resolved on future projects
ANTLE generated vast quantities of data, much of which requires more in depth analysisData obtained will compliment other existing and future R&T programmes