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ever since the first jumbo jet the
Boeing 747 made a revolution in the
airline industry back in the 70s
the need for jumbo jet engines has
become inevitable
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only a few companies in the world are
known to manufacture the engines that
take these 200 ton monsters to the skies
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for the leading aircraft engine
manufacturer like Rolls-Royce developing
a jet engine is a lengthsome process
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it is known for its finest and most
powerful engines powering the largest
known Airlines like Airbus super jumbo
and Boeing Dreamliner among others
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is one of the most expensive parts of
the plane about 11 000 people are
employed to build Rolls-Royce engines
across the manufacturing facilities in
the UK
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the Star product of the company is the
family of Trent engines with Trent 700
being its biggest seller and Trent xwb
the world's most efficient large civil
engine
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the latest generations of Trent are
characterized by lower emissions saving
Airlines millions of pounds in fuel
consumption
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the 140 million dollar Trent engine
weighs at least five tons and is built
for modules of eight separate sections
each module is made of hundreds of
components which are stored in the
massive Parts Warehouse
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the engine fan case housing the wiring
pipes and fan blades is where the
manufacturing starts
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unlike typical Jet fans this one is
designed to be hollowed for better
airflow
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at the heart of every engine is a ring
of 96 turbine blades which will Channel
air smoothly into the engine
Rolls-Royce employs software designers
to include the company's patented tiny
air holes to prevent the blade from
melting in the building process
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the front spinning large fan attachment
is the next step the enormous fan is
what distinguishes this jumbo jet engine
from older turbo Jets
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thank you
the blades are made from high quality
metal and are designed with World
beading performance and noise level
one fan has 20 blades each worth as much
as an average family car
weights are bolted on the inside to
balance the fan and ensure it works to
specifications any imbalance would cause
major problems for the engine
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the next step is to join the combustor
section to the enter case this is where
the engine with the shaft connects out
to the gearbox
once the final and biggest modules are
in place the engine is fitted with
aerodynamic ducts and is ready for
testing
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engine testing is perhaps the most
impressive part of manufacturing which
is usually conducted in a test bed
it's a big spacious room with a huge
structure keeping the engine in place
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testers explore how effectively the
engine handles starting up emergency
shutdowns and even run-ins with strange
objects while it is on the test bed
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is monitored to check for any imbalances
that can affect how the engine operates
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the fan blades of the engine also go
through vibration testing which includes
a nozzle blowing compressed air that
invokes flutter on the fan blade to
examine and evaluate its robustness
rolls-royce's biggest competitor General
Electric or GE Aviation is dealing
primarily in aircraft engines and
Avionics
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today thousands of employees work across
80 facilities spread throughout the
globe
equipped with high pressure compressors
lean burning combustors and lightweight
durable materials
the engines are well designed and
developed with over 1 billion dollars
spent yearly on the research and
development
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GE Aviation also became the first to
introduce composite fan blades in
commercial Aviation with their GE 90
engine which can be seen powering the
Boeing 777 Fleet
measuring more than four feet long and
weighing about 50 pounds each the GE 90
fan blade is made from carbon fiber and
a toughened epoxy Matrix
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the unique curved design makes it larger
lighter and more aerodynamic than
conventional titanium plates making the
ge-90 more efficient and economical
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the comprehensive test program includes
long-lasting icing tests ground runs fan
blade tests and many others to ensure
its air worthiness
once approved and certified the engines
can roll out for full production and
delivery to their respective aircraft
manufacturer
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for installation their engines are
placed into pods to prevent any direct
external damage to the engine and
provide Wing bending relief
the Potted engine is then attached to a
pylon which offers a safe distance
between the engine and the wing in case
the engine catches fire
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using robust super alloy bolts the pylon
is attached to the aircraft mounted
slightly forward of the wing to prevent
the wing from fluttering
while a great number of efforts are put
into the commercial airline sector a few
aircraft manufacturers such as Airbus
also Thrive towards offering robust
flying machines to the military
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for instance the Airbus a400m Atlas a
four engine turboprop military transport
aircraft designed as a Tactical Air
lifter with strategic capabilities
being deployed as a transport aircraft
its major component is fuselage which
entails a meticulous construction
process
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this process is first and most crucial
activity is positioning its fuselage
sections the sections must be perfectly
balanced to ensure the safety and
performance of the aircraft
3D printed devices are also used to
position brackets of the fuselage in a
timely and efficient manner
once the structural assembly is
completed the aircraft is then headed
toward the paint shop
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the process starts with applying a
surface protection on the inside of the
fuselage after which the Interiors are
completely sealed and the exteriors are
painted
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three coats of paint are applied to the
aircraft using a high volume low
pressure spray system to ensure an equal
coating
an environmentally friendly primer is
used first to prepare the surfaces for
the succeeding paint applications
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the next step is for the painters to
apply an undercoat of background color
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since the a400m is a military aircraft
it is expected to withstand extreme
missions during its service
consequently it goes through a series of
tests and qualifications such as
ground-based structural tests flight
test campaigns that include flying the
aircraft for more than ten thousand
hours
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besides private aerospace companies the
U.S Air Force has its own Air Force
research laboratory developing Advanced
manufacturing robots which will help
enhance human safety improve quality of
manufacturing as well as reduce costs
for instance the 22 000 pound A5 robotic
system is the first versatile robot
created for use on the Aerospace Factory
floor that can function in a confined
space using real-time sensor feedback
the A5 robot is expected to
significantly reduce Depot maintenance
periods for aircraft coating removal by
taking advantage of advances in man
machine interface technology saving time
and money throughout a platform
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the A5 is unique in that it can move
about an aircraft while using
cutting-edge sensors to perform
real-time path planning and Analysis
an on-board computer receives sensor
data evaluates it and sends an
operator's approval of an optimized
travel plan for maintenance operations
A5 can adapt to many platforms due to
this processing power without the
requirement for system reprogramming
which extends maintenance activities
time and expense
for the air space and cyberspace forces
the Air Force research laboratory takes
the lead in the research development and
integration of low-cost warfighting
Technologies
The Cutting Edge Technologies used in
modern jet propulsion have made a
tremendous impact on the development of
advanced powerhouses and aircraft today
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