Power runs of the world’s most powerful aerospace gearbox are now underway at the Rolls-Royce Power The Rolls-Royce Power Gearbox facility at Dahlewitz. (Source: Rolls-Royce)Gearbox (PGB) facility in Dahlewitz, Germany. The tests are expected to advance development of the new UltraFan® engine design. The gearbox will ultimately run at up to 100,000 horsepower – the equivalent of more than 100 Formula 1 cars.

The gearbox is a vital component of the UltraFan design, offering efficient power over a wide range of thrust levels, the ability to drive larger fan sizes, while also reducing weight. Available from 2025, UltraFan will offer a 25 percent fuel efficiency improvement over the first generation of Rolls-Royce Trent engine, with power scalable for wide-body or narrow-body aircraft.

UltraFan features include:

• Maximum fuel burn efficiency and low emissions through a new engine core architecture
• Reduced weight via a Fan System of carbon/titanium (CTi) fan blades and a composite casing
• Increased efficiency through advanced ceramic matrix composites that are heat resistant and require less cooling air
• Efficient power for high-bypass ratio engines of the future through a geared design

Attitude Rig tests have already been completed, allowing engineers to simulate the effects of the gearbox on the wing of an aircraft in flight, through phases such as take-off, climb, descent, and landing or banking.

Rolls-Royce is working in partnership with Liebherr-Aerospace, through its Aerospace Transmission Technologies joint venture, to develop manufacturing capability and capacity for the new power gearbox. Rolls-Royce leads the design definition and design integration of the power gearbox, as well as testing activities.