Engineering of an Engine Mounting Frame for S&C Thermofluids
TECHNIA partnered with S&C Thermofluids to create an optimized engine mounting frame using integrated engineering, resulting in a successful installation that enabled timely testing.
Challenge
S&C Thermofluids needed a validated engine mounting frame design that was functional and optimized for rapid manufacture, material efficiency, and structural performance.
Solution
TECHNIA engineers took an integrated approach to design and simulation of multiple engine mounting frame options, delivering approved manufacturing drawings of the preferred design.
Results
The project successfully delivered an engine mounting frame that met S&C Thermofluids’ requirements, enabling them to commence their testing program on schedule.
Affordable and accurate testing of e-propulsion systems
S & C Thermofluids embarked on addressing the challenge faced by e-propulsion companies, namely the lack of affordable and accurate test facilities for full-scale dynamic testing of e-propulsion systems, particularly in the early development stages. Existing options, including wind tunnels and truck-based dynamic testing, are either too expensive or lack accuracy and repeatability.
To solve this, S&C Thermofluids collaborated with other industry partners to develop the e-KETL (Kemble Engine Test Laboratory) test site project, funded through an NATEP (National Aerospace Technology Exploitation Programme) grant. This novel facility utilizes an ejector principle to create a modular, cost-effective wind tunnel capable of simulating various e-propulsor conditions.
Validating the design of an engine mounting frame
S&C Thermofluids required a validated design of an engine mounting frame that was not only functional but also optimized for rapid manufacture, material usage, and structural performance.
Simulation-driven design of an engine mounting frame
S&C Thermofluids partnered with TECHNIA to design an engine mounting frame to perform initial commissioning test on the proposed gas turbine engine to drive the air flow in the wind tunnel. Although the necessary mounting gantry and gas turbine engine were available, S&C Thermofluids required a mounting frame that could seamlessly integrate those components.
TECHNIA’s design and simulation teams developed the initial concepts into several design options. After presenting these options to S&C Thermofluids, the preferred design solution was selected for development and optimization. Our simulation team then conducted a structural analysis to validate the design integrity and optimize material usage in the final solution.
Delivering approved manufacturing drawings in preparation for testing
The final delivery included checked and approved manufacturing drawings that were ready for the mounting frame to be fabricated. The project resulted in the successful creation and installation of the engine mounting frame at S&C Thermofluids KETL facility. This project exemplifies our integrated engineering approach, combining design and simulation to deliver a robust solution. The completed mounting frame met customer requirements, enabling S&C Thermofluids to begin their testing program according to the required project schedule.
