Rotating Connect/Disconnect Under Load

Project goal: To develop a prototype mechanism to mechanically connect and disconnect a gas turbine auxiliary power unit from the load compressor on large commercial aircraft. A review of existing mechanisms indicated that some type of clutch system would be required, and trade studies led to the selection of a design based on a synchro-mesh blocker ring. The first generation of the rotating connect/disconnect was developed and tailored to the sponsor’s torque, centrifugal and thermal load requirements and dimensional constraints. The first-generation mechanism was then evaluated under worst-case scenarios using a combination of manual and finite element analysis. Design aspects that did not meet performance requirements were identified then iteratively modified and re-evaluated until all performance requirements were met. Through this process a final generation mechanism was created and a 3-D printed demonstrator unit produced.