Past, present and future sustaining the traditions of Sir Henry Royce Philip Ruffles CBE, FRS, FREng former Director of Engineering and Technology, Rolls-Royce plc The 30th Sir Henry Royce Memorial Lecture The Institute of Engineering and Technology 3 May 2012
Sir Henry Royce
Rolls meets Royce
A family of cars
The Silver Ghost It is the best six cylinder car in the world I may say my car is a perfect dream. It is so reliable that I have done away with my carriages and horses
The Eagle, the first aero engine Royce s detailed notes that depicted his engineering approach to the development of the Eagle were reproduced for the benefit of Rolls-Royce engineers, in a bound volume that came to be known as The Bible
A family of piston engines V6 Hawk 1915 75-105 hp V12 Eagle 1915 225-360 hp V12 Falcon 1916 230-285 hp V12 Condor 1920 600-750 hp V12 Kestrel 1927 450-720 hp V12 Buzzard 1927 800-955 hp V12 R 1929 1400-2530 hp V12 Merlin PV12 1935 740-2060 hp Data shows first delivery and range of power achieved V12 Peregrine 1938 885 hp V12 Griffon 1940 1730-2420 hp
Sir Henry Royce A visionary who understood his market and customers A brilliant designer and engineer whose strive for excellence was without bounds Believed in building on known practice and did not suffer from Not invented here. He once said I invent nothing inventors go broke Used rigorous testing including overload and extreme tolerances to advance his designs Would only accept the very best. Laid down the standards that pertain to the present day Exceptionally hard worker to the detriment of his health
The need for a new large engine
RB178-51 for Boeing B747 Advantages of three shafts Optimum aerodynamics Short rigid engine Fewer stages Better modularity Improved operation Better growth potential Good performance retention
Events leading up to launch of RB211 March 1966 American Airlines issued requirement for a new 265 seat short/medium range aircraft Lockheed and McDonnell Douglas study aircraft for American Airlines requirement Airbus consortium forming to develop a new twin aircraft Rolls-Royce offers RB207 (a scale of RB178-51) to all three aircraft manufacturers November 1966 Trijet considered, Rolls-Royce offers RB211-06 of 33,260lb thrust July 1967 Trijet selected by TWA initially March 1968 Lockheed announce launch of Tristar powered by RB211-22 engine (of 40,600lb thrust)
The launch 29 March 1968 Order placed for 450 engines (150 planes)
RB211-06 and RB211-22 Designed for market leadership through technology RB211-06 33,260lb thrust RB211-22 40,600lb Uprated to 42,000lb in 1970 Three shaft architecture Hyfil fan blade Composite front structure Annular combustor High temperature turbines
Early design changes and development problems Engine overweight Fan blade integrity Deletion of composites and strengthening of engine structure Poor performance of compressors and turbines Temperature traverse LP blade profile changes Operability IP NGV performance Change to fan case mount and external gearbox Combustion chamber and NGV cooling, cracking and collapse HP turbine blade cooling/fatigue (IPNGV excitation)
Memorable moments 40,000lb thrust achieved March 1969 Performance demonstrated 3 February 1971
Milestones achieved Mid 1967 March 1968 August 1968 January 1970 March 1970 November 1970 February 1972 April 1972 February 1973 RB211-06 detailed design commenced at 33,260lbs thrust RB211-22 order received at 40,600lbs thrust First run of -06 engine First run of -22 engine First flight of RB211 in VC10 First flight of L1011 Type approval obtained for 42,000lbs at ISA+3.8C, 38,750lb at ISA+13.9C L1011 obtains type approval airline service starts four and a half months late Type approval obtained in February 1973 for 42,000lb at ISA+13.9C (-22B)
RB211-524 and RB211-535
Trent 700 derivation from RB211-524 New 8 stage IPC Cast Titanium intercase Phase V combustor Fan diameter 2.47m (97.4in) New 4 stage LPT SPF/DB wide chord fan -524G-H HP system with improved HP aerodynamics
The Trent family EIS TBC Trent XWB 84,000lb & 97,000lb EIS 1996 Trent 800 95,000lb EIS 2007 Trent 900 80,000lb EIS 2009 Trent 1000 74,000lb EIS 2002 Trent 500 56,000lb EIS 1995 Trent 700 72,000lb EIS 1998 RB211-524G/H-T 60,000lb 2020 Trent engines delivered 2300 Trent engines on order (as of April 2012)
Trent technology advances Whole engine Contra-rotating HP system IP shaft power off take Low Noise Technology Fan system 2nd Generation SPF/DB WCFB Swept design Ribbed Armco Containment Swept OGV Compressors 3D Compressor aerodynamics Active anti icing Cast Ti Intercase Combustor Low NOx Tiled Design Turbines Single Crystal Materials Advanced Coatings 3D Aerodynamics High strength disc materials Soluble core technology Controls FADEC More electric accessories Health monitoring
Wide-chord fan technology Clappered Hollow wide-chord fan First generation Second generation Swept Third generation Higher efficiency Lower noise High damage resistance Low weight Low noise Low weight High efficiency High flow Solid Honeycomb DBSPF* girder DBSPF* girder 1970s 1984 1995 Current
Bird strike test
Fan blade off test
Turbine blade technology Improvements in materials Cooling technology Gas stream temperature exceeds blade material melting temperature by 350 degrees Celsius Trent 900 Multi-pass Single crystal HP blade Equiaxed crystal structure Directionally solidified structure Single crystal Trent 1000 Soluble core Single crystal HP blade Increasing manufacturing capability for more effective internal geometry Thermal barrier coating
Striving to achieve global environmental targets (Advisory Council for Aeronautics Research in Europe) Trent 1000 is 12 per cent more fuel efficient than Trent 800
Other RB211 & Trent applications Industrial RB-211 Marine WR21 Marine MT30 Aero Trent Industrial Trent 60 MT30
Future aircraft projects Possible short range aircraft Possible long range aircraft
Past, present and future in the tradition of Sir Henry Royce Purpose To manufacture, sell, or let on hire, or in any manner dispose of or turn to account, motor vehicles for use on land or water or in the air Extract from the Memorandum of Association of Rolls-Royce Limited - 1906 Principles Good architecture Continuous innovation Well researched and demonstrated technology platforms A family approach Good processes Good people