Method of forming a dual-structure aircraft engine starter / generator apparatus

Abstract

A method for manufacturing a dual-structure aircraft engine starting and power generation device is provided. The method includes using a three-dimensional printing process to print a housing comprising a main engine portion and an exciter portion for receiving at least a portion of a generator system. Printing the housing includes printing a cooling jacket portion comprising one or more cooling channels, the cooling jacket portion being an integral part of a sidewall of the housing.

Description

Technical Field

[0001] The present specification relates generally to starter / generator apparatuses and, more particularly, to starter / generator apparatuses and methods of forming starter / generator apparatuses using three-dimensional printing. Background Art

[0002] Some current aircraft engines include a starter / generator device that functions as an electric motor for starting the aircraft engine and as a generator for supplying electrical energy to an electrical system on the aircraft after starting the aircraft engine. In this regard, the starter / generator device has a starting mode for converting electrical energy into mechanical energy and a power generation mode for converting mechanical energy into electrical energy.

[0003] Conventional methods for forming starter / generator devices can include any number of manufacturing processes, such as machining, casting, stamping, lamination, and the like. For example, stamped oxide laminations can be stacked to form the core, and the coils can be formed from insulated wire. A housing can be used to house the various separately formed components. These methods can form reliable electric motors; however, there may be many separately formed components assembled together, which increases weight and cost. Therefore, there is a need for methods for forming starter / generator devices using 3D printing to integrate the various components into a single part. Summary of the Invention

[0004] In one embodiment, a method for manufacturing a dual-structure aircraft engine starting and power generation device is provided. The method includes using a three-dimensional printing process to print a housing comprising a main engine portion and an exciter portion for receiving at least a portion of a generator system. Printing the housing includes printing a cooling jacket portion comprising one or more cooling channels, the cooling jacket portion being an integral part of a sidewall of the housing.

[0005] In another embodiment, an aircraft engine starting and power generation apparatus includes a 3D-printed housing and a generator system. The generator system includes a main stator positioned within the housing, a main rotor positioned within a cavity of the main stator, an exciter stator positioned within the housing, and an exciter rotor positioned within the cavity of the exciter stator. The housing includes a cooling jacket portion including one or more cooling channels, the cooling jacket portion being an integral part of a sidewall of the housing.

[0006] Additional features and advantages of the starter / generator apparatus described herein and methods of forming the starter / generator apparatus will be set forth in the detailed description that follows and, in part, will be readily apparent to those skilled in the art from that description or will be recognized by practicing the embodiments described herein, including the subsequent detailed description, claims, and accompanying drawings.

[0007] It should be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein and, together with the description, serve to explain the principles and operation of the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG1 is a perspective view of a known aircraft engine starting and power generation device;

[0009] Figure 2 A method of forming a dual-structure aircraft engine starting and power generation apparatus according to one or more embodiments shown and described herein is shown;

[0010] Figure 3 is a schematic cross-sectional view of an aircraft engine starting and power generation apparatus according to one or more embodiments shown and described herein;

[0011] Figure 4 is a schematic cross-sectional view of an aircraft engine starting and power generation apparatus according to one or more embodiments shown and described herein;

[0012] Figure 5A It is along Figure 4 a cross-sectional view of the aircraft engine starting and power generation equipment along line 5-5;

[0013] Figure 5B is along the lines of one or more embodiments shown and described herein Figure 5A Schematic diagram of the cooling passage of the cooling jacket of the housing of the aircraft engine starting and power generation equipment according to line 5B-5B;

[0014] Figure 6 is a schematic diagram of layers of an enclosure for an aircraft engine starting and power generation apparatus according to one or more embodiments shown and described herein; and

[0015] Figure 7 Another embodiment of an aircraft engine starting and power generation apparatus is shown in accordance with one or more embodiments shown and described herein. DETAILED DESCRIPTION

[0016] One embodiment of a dual-structure aircraft engine starting and power generation apparatus includes a first generator assembly, the first generator assembly including a first exciter and a first main engine. The starting and power generation apparatus includes a second generator assembly, the second generator assembly including a second exciter and a second main engine. The first and second main engines may include a main rotor and a main stator that may be formed at least in part through a three-dimensional (3D) printing process. Similarly, the first and second exciters may include an exciter rotor and an exciter stator that may be formed at least in part through a 3D printing process.

[0017] The first and second generator assemblies can be located within a housing that houses their respective first exciter, first host, and second exciter and second host. The housing can also be at least partially formed via a 3D printing process. The cooling jacket of the housing can be integrally formed as an integral part of the sidewalls of the housing. The end walls of the housing can also be 3D printed as an integral, integral part of the housing.

[0018] 3D printing of the first and second generator assemblies can also provide the ability to integrate other components that would otherwise be formed separately and connected together, which can reduce the weight and complexity of the assembly. As an example, the front bearing assemblies of the first and second generator assemblies can be eliminated, as shown and described in U.S. Patent No. 7,687,928, filed on May 3, 2007, the details of which are incorporated herein by reference. As another example, cooling oil pipes can be integrated into the first and second generator assemblies. As another example, the rotor shafts and rotor cores of the first and second main engines can be formed as a single, integral part. For example, suitable materials for forming the various components may be cobalt iron or silicon iron.

[0019] The term "additive manufacturing" and the like generally refer to a manufacturing process in which successive layers of material are applied one after another to build up a three-dimensional part layer by layer. The layers are typically fused together to form a monolithic part. Examples of additive manufacturing techniques include fused deposition modeling (FDM), selective laser sintering (SLS), 3D printing (e.g., by inkjet and laser jetting), stereolithography (SLA), direct laser sintering (DSLS), electron beam sintering (EBS), electron beam melting (EBM), laser engineered net shape (LENS), laser net shape manufacturing (LNSM), direct metal deposition (DMD), digital light processing (DLP), direct selective laser melting (DSLM), selective laser melting (SLM), direct metal laser melting (DMLM), and the like. Additive manufacturing processes can allow a single part to be built using a variety of different materials.

[0020] As used herein, the term "three-dimensional structure" or the like generally refers to an intended or actually manufactured three-dimensional configuration (e.g., a three-dimensional configuration of one or more structural materials) intended for a specific purpose. For example, such a structure can be designed with the aid of a computer-aided design (CAD) program.

[0021] As used herein, the term "two-dimensional structure" and the like generally refers to layers of a three-dimensional structure that, when built up, one layer on top of another, form a three-dimensional structure. Although referred to as a "two-dimensional structure," it should be understood that each layer includes an accompanying thickness in the third dimension, although these structures have a relatively planar configuration compared to the fused stacking of two-dimensional structures that form a three-dimensional structure.

[0022] Ranges may be expressed herein as from "about" one particular value and / or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values ​​are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each range are significant relative to the other endpoint, and independent of the other endpoint.

[0023] Directional terms used herein (eg, up, down, right, left, front, back, top, bottom, above, below) refer only to the drawings as drawn and are not intended to imply an absolute orientation unless expressly stated otherwise.

[0024] Unless expressly stated otherwise, any method described herein is not intended to be construed as requiring that its steps be performed in a specific order, nor is it intended to require any particular orientation of the apparatus. Therefore, in no respect is an order or orientation to be inferred if a method claim does not actually recite the order in which its steps are to be performed, or if any apparatus claim does not actually recite the order or orientation of individual components, or if steps are not otherwise specifically stated in the claim or specification to be limited to a specific order, or if a specific order or orientation of apparatus components is not mentioned. This applies to any possible non-express basis for interpretation, including: problems of logic relating to arrangement of steps, operational flow, order of components, or orientation of components; plain meaning derived from grammatical organization or punctuation; and the number or type of embodiments described in the specification.

[0025] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a" component includes aspects having two or more such components unless the context clearly dictates otherwise.

[0026] Referring to FIG. 1 , a known dual-engine aircraft engine starting and generating apparatus 1 is shown. As can be seen, the starting and generating apparatus 1 includes a housing 2 that houses two generator systems, including a main engine section 3, an exciter section 4, and a PMG section 6. The starting and generating apparatus 1 also includes a plurality of oil pipes 8 attached to the housing 2. The housing 2 is sufficiently large to accommodate the two generator systems. As can be appreciated, the starting and generating apparatus 1 is relatively large and heavy. Reducing the size of the starting and generating apparatus 1 and integrating its components would be beneficial.

[0027] refer to Figure 2 , illustrates an embodiment of a method 10 for forming a dual-structure aircraft engine starting and power generation device. Method 10 includes printing a first main rotor at step 12. At step 14, a second main rotor may be printed. In some embodiments, the main rotor may be printed with both the rotor core and the rotor shaft as a single, integral component. In other embodiments, the rotor core and the rotor shaft, or at least portions thereof, may be printed separately and then joined together. At step 16, a first main stator may be printed, and at step 18, a second main stator may be printed. In some embodiments, the first and second main stators may be printed as part of the outer shell. In other embodiments, the first and second main stators may be printed separately from the outer shell and then joined to the outer shell. At step 20, a first exciter rotor may be printed. At step 22, a second exciter rotor may be printed. In some embodiments, the exciter rotor may be printed with both the rotor core and the rotor shaft as a single, integral component. At step 24, the first exciter stator may be printed, and at step 26, the second main stator may be printed. In some embodiments, the first and second exciter stators may be printed as part of the outer shell. In other embodiments, the first and second main stators may be printed separately from the outer shell.

[0028] A first generator housing for the first generator assembly may be printed at step 28. A second generator housing for the second generator assembly may be printed at step 30. As will be discussed below, the generator housings may each be printed with a liquid cooling jacket and / or air cooling fins such that the liquid cooling jacket and / or air cooling fins are an integral, unitary part of the housing. At step 32, a permanent magnet generator (PMG) rotor may be printed, and at step 34, a PMG stator may be printed. At step 36, a gear housing may be printed that may hold the PMG rotor and stator. In some embodiments, the PMG stator may be printed as part of the gear housing. In other embodiments, for example Figure 7 As shown, the PMG can be located at least partially outside the gear housing.

[0029] refer to Figure 3, shows a schematic diagram of an assembled dual-configuration engine starting and power generation system 40. The engine starting and power generation system 40 includes an engine starting and power generation device 42, a stub shaft 44, and a pair of inverter converter controllers (ICCs) 46 and 48 connected to the engine starting and power generation device 42. The engine starting and power generation device 42 can be mounted on the engine gearbox, for example, using a quick attach / detach (QAD) band clamp and coupled to the engine gearbox via the stub shaft 44. In some embodiments, the engine starting and power generation device 42 can be oil-cooled and lubricated. The engine starting and power generation device 42 includes a speed increaser gear train 50 and a permanent magnet generator (PMG) 52 at the input stage. The speed increaser gear train 50 can include parallel shaft outputs 54 and 56, which are connected to two synchronous winding machines, referred to as generator systems 58 and 60. The generator systems 58 and 60 each include a main synchronous winding machine 62 and 64 and an exciter 66 and 68.

[0030] Each ICC 46 and 48 may be a line replaceable unit (LRU) that is a solid-state component for fuel cooling. The ICCs 46 and 48 may be identical and connected to each of the two generator systems 58 and 60 within the engine starting and power generation equipment 42 via various power and control cables. Both ICCs 46 and 48 are connected to the internal aircraft power supply.

[0031] refer to Figure 4 The assembled dual-structure aircraft engine starting and power generation apparatus 100 can be formed using the above-described method and includes a first generator system 102 and a second generator system 104. Each of the first generator system 102 and the second generator system 104 is a combination of three electric machines, including main machines 106 and 108, exciters 110 and 112, and a permanent magnet generator (PMG) 114. The first main machine 106 includes a first main stator 118 and a first main rotor 120 located within a cavity 122 of the first main stator 118. The first main stator 118 includes a first stator core 124 and a plurality of windings 126 wound around pole bodies forming stator poles. The first main rotor 120 also includes a plurality of windings 125 wound around pole bodies forming rotor poles. Similarly, the first exciter 110 includes a first exciter stator 128 and a first exciter rotor 130. The first exciter stator 128 may include a plurality of windings 132 wound around pole bodies forming stator poles. The first exciter rotor 130 may also include a plurality of windings 134 wound around pole bodies forming rotor poles. The PMG 114 also includes a PMG stator 136 and a PMG rotor 138. The PMG stator 136 may include a plurality of windings 140 wound around pole bodies forming stator poles. The PMG rotor 138 may include rotor poles formed by permanent magnets 142.

[0032] Second main machine 108 includes a second main stator 144 and a second main rotor 146 located within a cavity 148 of second main stator 144. Second main stator 144 includes a second stator core 150 and a plurality of windings 152 wound around pole bodies forming stator poles. Second main rotor 146 also includes a plurality of windings 154 wound around pole bodies forming rotor poles. Second exciter 112 includes a second exciter stator 156 and a second exciter rotor 157. Second exciter stator 156 may include a plurality of windings 158 wound around pole bodies forming stator poles. Second exciter rotor 157 may also include a plurality of windings 160 wound around pole bodies forming rotor poles.

[0033] The first and second mainframes 106, 108, the first and second exciters 110, 112, and the multiple rotor poles of the PMG 114 can generate multiple magnetic fields relative to the stator poles, so that the device 100 can operate to generate force or electricity through the interaction of the magnetic fields and the current-carrying conductors. The first and second exciters 110, 112 can provide direct current to the first and second mainframes 106, 108, and when the PMG rotor 138 rotates, the first and second mainframes 106, 108 and the PMG 114 can provide AC power.

[0034] The device 100 can be oil-cooled and, therefore, can include a cooling system 170. Cooling oil can be used to dissipate heat generated by the electrical and mechanical functions of the device 100. The cooling system 170 can also use oil to lubricate the device 100. In the illustrated aspect, the device 100 can be configured to operate as a dry chamber system. The cooling system 170 can include, for example, a cooling fluid reservoir and various cooling channels. The rotor shafts 174, 176 can provide one or more flow channels or paths that couple the rotor shafts 174, 176 with a plurality of enclosed flow channels 178, 180. The flow channels 178, 180 can enable the flow of a cooling fluid (e.g., oil) for the main rotors 120, 146. In some embodiments, the cooling system 170 can be configured to operate as a wet chamber system or as a combination of a wet chamber system and a dry chamber system.

[0035] Also refer to Figure 5AHousings 105 and 107 are 3D-printed and each formed as a single, unitary structure. Housing 105 includes sidewalls 182, a rear wall 184, and a front wall 186 connected to a gear housing 188. Sidewall 182 may include one or more cooling channels 190 integrally formed therewith during the 3D printing process. Cooling channels 190 may be used to deliver cooling and lubricating oil directly to bearing assemblies 196 and 198 in gear housing 188. Sidewall 182 may also include a cooling jacket portion 192, also formed as part of housing 105. Cooling jacket portion 192 includes cooling channels 194, through which cooling oil can flow to remove heat from housing 105. Cooling channels 190 are wider than cooling channels 194, which form part of cooling jacket portion 192. Forming housing 105 as a single, unitary piece and integrating cooling channels 190 and 194 can reduce the overall weight of engine starting and power generation equipment 100 by reducing the number of separate components and the amount of material.

[0036] Like housing 105, housing 107 includes sidewalls 183, a rear wall 185, and a front wall 187 connected to a gear housing 188. Sidewall 183 may include one or more cooling channels 191 integrally formed therewith during the 3D printing process. Cooling channels 191 may be used to deliver cooling and lubricating oil directly to bearing assemblies 196 and 198 in gear housing 188. Sidewall 183 may also include a cooling jacket portion 193, also formed as part of housing 107. Cooling jacket portion 193 includes cooling channels 195, through which cooling oil can flow to remove heat from housing 107. Cooling channels 191 are wider than cooling channels 195, which form part of cooling jacket portion 193. Forming housing 107 as a single, unitary piece and integrating cooling channels 191 and 195 can reduce the overall weight of engine starting and power generation equipment 100 by reducing the number of separate components and the amount of material. In some embodiments, gear housing 188 may also be 3D printed as a single, unitary piece of material, which can further reduce weight. In some embodiments, the gear housing 188 may also be 3D printed as a single, unitary piece of material, which may further reduce weight.

[0037] refer to Figure 5B The cooling channels 195 can be a network of channels extending both circumferentially and axially. In the example shown, the axial cooling channels 195a and the circumferential cooling channels 195b intersect, allowing the cooling fluid to flow both circumferentially and axially. Other channel arrangements are possible, such as channels extending only axially or only circumferentially. In some embodiments, the cooling channels can form a spiral that extends both circumferentially and axially. Any suitable shape for the cooling channels can be used.

[0038] Figure 6An example layer 300 of a 3D printed housing 105 is diagrammatically depicted. The layer 300 defines an axial direction A, a radial direction R, and a circumferential direction C extending 360 degrees around the axial direction A. The axial direction A extends into and out of the page. The layer can be printed using any suitable material.

[0039] Layer 300 is printed to include a body portion 302 and oil channels 190. Cooling jacket portion 192 is printed as part of body portion 302 and includes flow channels 194 that can extend around the entire periphery of body portion 302. Flow channels 194 can extend longitudinally in any suitable axial and circumferential directions, or both. Although flow channels 194 are shown as being spaced apart in the circumferential direction, flow channels 194 can be interconnected to form a continuous flow channel on outer shell 105 formed from multiple layers.

[0040] Reference again Figure 4 , the engine starting and power generation device 100 may include end bells 200 and 202, each of which includes bearing assemblies 204 and 206 that rotatably support the rotating shafts 174 and 176. Typical engine starting and power generation devices (such as the device described in US7,687,928 and the device depicted in Figure 1) include another end bell at the drive end of the engine starting and power generation device. These end bells also include bearing assemblies. However, in this embodiment, the drive end bearing assembly is eliminated using a 3D printing process because improved tolerances can be achieved between the housing 105 and the shafts 174 and 176. Eliminating the bearing assembly can further reduce the weight of the engine starting and power generation device 100 and improve its efficiency.

[0041] Any other components of the starting and power generation device 100 can be formed by additive manufacturing. For example, the exciter and any of the PMG rotors and stators can be 3D printed.

[0042] Printing housings and other components for engine starting and power generation equipment can also provide flexibility in the design of engine starting and power generation equipment. For example, Figure 7 Another engine starting and power generation device 310 includes a first generator system 312 and a second generator system 314 similar to those described above. In this embodiment, a space 316 is provided between the first and second generator systems 312 and 314 during the additive manufacturing process, which is suitable for receiving a PMG 318. The PMG 318 is operably linked to the first and second generator systems 312 and 314 via a gear 320. Bearings 322, 324, 326, 328, 330, and 332 may be provided to support a stub shaft 340 and generator shafts 342 and 344.

[0043] The engine starting and power generation equipment described above was constructed using additive manufacturing, with the oil passages and cooling jacket integrated into the housing rather than being formed from separate components and added to the housing. Due to the precision of the 3D printing process, the front bearing could be eliminated. By eliminating components and reducing material, the weight of the engine starting and power generation equipment can be reduced and efficiency can be improved. Furthermore, the use of additive manufacturing allows for design changes in the engine starting and power generation equipment, which can also reduce weight and improve efficiency.

[0044] Further aspects of the invention are provided by the subject matter of the following clauses:

[0045] Item 1. A method for manufacturing a dual-structure aircraft engine starting and power generation device, the method comprising: using a three-dimensional printing process to print a housing including a main body portion and an exciter portion for receiving at least a portion of a generator system; and wherein the step of printing the housing includes printing a cooling jacket portion, the cooling jacket portion including one or more cooling channels and being an integral part of the side wall of the housing.

[0046] Clause 2. The method of any preceding clause, wherein the step of printing the housing includes printing another cooling channel having a width greater than the one or more cooling channels that are part of the cooling jacket.

[0047] Clause 3. The method of any preceding clause, wherein the step of printing the housing comprises printing a plurality of cooling channels as part of the cooling jacket portion.

[0048] Clause 4. The method of any preceding clause, wherein the plurality of cooling channels comprises axially extending cooling channels and circumferentially extending cooling channels that intersect the axially extending cooling channels.

[0049] Item 5. A method according to any preceding item, wherein the housing is a first housing, the method further comprising: using a three-dimensional printing process to print a second housing comprising a host portion and an exciter portion for receiving at least a portion of another generator system; and wherein the step of printing the second housing comprises printing a second cooling jacket portion, the second cooling jacket portion comprising one or more cooling channels and being an integral part of the side wall of the second housing.

[0050] Clause 6. The method of any preceding clause, wherein the step of printing the second housing includes printing another cooling channel having a width greater than the one or more cooling channels of the second housing that are part of the cooling jacket of the second housing.

[0051] Clause 7. The method of any preceding clause, wherein the step of printing the second housing comprises printing a plurality of cooling channels as part of the cooling jacket portion of the second housing.

[0052] Clause 8. The method of any preceding clause, wherein the plurality of cooling channels of the second outer casing includes axially extending cooling channels and circumferentially extending cooling channels that intersect the axially extending cooling channels of the second outer casing.

[0053] Clause 9. The method of any preceding clause, further comprising: positioning at least a portion of a first generator system in the first enclosure; and positioning at least a portion of a second generator system in the second enclosure.

[0054] Clause 10. The method of any preceding clause, further comprising connecting the first housing and the second housing to a gear housing such that the first generator system and the second generator system are both operably connected to a permanent magnet generator located at least partially outside the gear housing.

[0055] Clause 11. A method according to any preceding clause, wherein the first generator system is connected to the permanent magnet generator via a first output shaft without using a drive end bearing connected to the first housing, and the second generator system is connected to the permanent magnet generator via a second output shaft without using a drive end bearing connected to the second housing.

[0056] Item 12. A method according to any preceding item, wherein the step of printing the second housing includes: printing another cooling channel, the width of which is greater than the one or more cooling channels that are part of the cooling jacket; and aligning the another cooling channel with a third cooling channel, the third cooling channel extending axially through the gear housing to the bearing assembly in the gear housing.

[0057] Item 13. An aircraft engine starting and power generation device comprising: a three-dimensional printed housing; and a generator system, the generator system comprising: a main stator, the main stator being located in the housing; a main rotor, the main rotor being located in a cavity of the main stator; an exciter stator, the exciter stator being located in the housing; and an exciter rotor, the exciter rotor being located in the cavity of the exciter stator; wherein the housing includes a cooling jacket portion, the cooling jacket portion including one or more cooling channels, and being an integral part of a side wall of the housing.

[0058] Clause 14. The apparatus of any preceding clause, wherein the housing comprises another cooling channel having a width greater than the one or more cooling channels that are part of a cooling jacket, the other cooling channel being three-dimensionally printed with the housing.

[0059] Item 15. An apparatus according to any preceding item, wherein the housing is a first housing, the apparatus further comprising a three-dimensionally printed second housing, the second housing comprising another cooling jacket portion, the other cooling jacket portion comprising one or more cooling channels and being an integral part of a side wall of the second housing.

[0060] Item 16. An apparatus according to any preceding item, wherein the generator system is a first generator system, and the apparatus further includes a second generator system, the second generator system including: a second main stator, the second main stator being located in the second housing; a second main rotor, the second main rotor being located in the cavity of the main stator; a second exciter stator, the second exciter stator being located in the second housing; and a second exciter rotor, the second exciter rotor being located in the cavity of the exciter stator; wherein the first housing and the second housing are connected to a gear housing so that both the first generator system and the second generator system are operably connected to a permanent magnet generator located inside the gear housing.

[0061] Clause 17. An apparatus according to any preceding clause, wherein the first generator system is connected to the permanent magnet generator via a first output shaft without using a drive end bearing mounted to the first housing, and the second generator system is connected to the permanent magnet generator via a second output shaft without using a drive end bearing mounted to the second housing.

[0062] Clause 18. An apparatus according to any preceding clause, wherein the second housing includes another cooling channel having a width greater than the one or more cooling channels that are part of the other cooling jacket of the second housing, the other cooling channel being three-dimensionally printed together with the second housing.

[0063] Clause 19. The apparatus of any preceding clause, wherein the cooling jacket portion comprises a plurality of cooling channels and is an integral part of the side wall of the housing.

[0064] Clause 20. The apparatus of any preceding clause, wherein the plurality of cooling channels comprises axially extending cooling channels and circumferentially extending cooling channels that intersect the axially extending cooling channels.

[0065] It will be apparent to those skilled in the art that various modifications and variations may be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Therefore, this specification is intended to cover modifications and variations of the various embodiments described herein, provided that such modifications and variations fall within the scope of the appended claims and their equivalents.

Claims

1. A method for manufacturing a dual-structure aircraft engine starting and power generation device, characterized in that: The method comprises: printing a housing comprising a mainframe portion and an exciter portion for receiving at least a portion of the generator system using a three-dimensional printing process; and wherein the step of printing the housing includes printing a cooling jacket portion, the cooling jacket portion being an integral part of a side wall of the housing and comprising a plurality of cooling channels, wherein the plurality of cooling channels include an axially extending first cooling channel and a circumferentially extending second cooling channel intersecting the axially extending first cooling channel, wherein the circumferentially extending second cooling channels are continuous around the circumference of the cooling jacket portion such that each circumferentially extending second cooling channel intersects a plurality of axially extending first cooling channels, wherein the housing is a first housing, positioning at least a portion of a first generator system within the first housing; coupling the first housing to a gear housing such that the first generator system is operatively connected to a permanent magnet generator at least partially located outside the gear housing; The first generator system is connected to the permanent magnet generator via a first output shaft, using only a single bearing assembly connected to the first housing.

2. The method according to claim 1, characterized in that The step of printing the first housing includes printing a further cooling channel that is larger than the plurality of cooling channels that are part of the cooling jacket.

3. The method according to claim 1, characterized in that The method further comprises: printing a second housing comprising a mainframe portion and an exciter portion using a three-dimensional printing process for receiving at least a portion of another generator system; and The step of printing the second shell includes printing a second cooling jacket portion, the second cooling jacket portion including one or more cooling channels and being an integral part of the side wall of the second shell.

4. The method according to claim 3, characterized in that Wherein the step of printing the second housing includes printing a further cooling channel that is larger than the one or more cooling channels of the second housing that are part of the cooling jacket of the second housing.

5. The method according to claim 3, characterized in that Wherein the step of printing the second housing includes printing a plurality of cooling channels as part of the cooling jacket portion of the second housing.

6. The method according to claim 5, characterized in that The plurality of cooling channels of the second housing include axially extending cooling channels and circumferentially extending cooling channels intersecting the axially extending cooling channels of the second housing.

7. The method according to claim 3, characterized in that Further including: At least a portion of a second generator system is positioned within the second enclosure.

8. The method according to claim 7, characterized in that Further comprising coupling the second housing to the gear housing such that the second generator system is operably coupled to the permanent magnet generator at least partially external to the gear housing.

9. The method according to claim 8, characterized in that The second generator system is connected to the permanent magnet generator via a second output shaft, using only a single bearing assembly connected to the second housing.

10. The method according to claim 8, characterized in that The step of printing the second housing includes: printing another cooling channel, the another cooling channel being larger than the one or more cooling channels that are part of the cooling jacket; and aligning the another cooling channel with a third cooling channel, the third cooling channel extending axially through the gear housing to a bearing assembly in the gear housing.

11. The method according to claim 1, characterized in that The cross-sectional shapes of the axially extending first cooling channel and the circumferentially extending second cooling channel are rectangular.

12. The method according to claim 1, characterized in that The circumferentially extending second cooling channel extends circumferentially in a spiral shape.

13. An aircraft engine starting and power generation device, characterized in that: include: 3D-printed housing; as well as A generator system, comprising: a main stator, the main stator being located in the housing; a main rotor located in a cavity of the main stator; an exciter stator positioned within the housing; and an exciter rotor positioned in a cavity of the exciter stator; wherein the housing includes a cooling jacket portion, the cooling jacket portion including a plurality of cooling channels, and is an integral part of a side wall of the housing, wherein the plurality of cooling channels include an axially extending first cooling channel and a circumferentially extending second cooling channel intersecting the axially extending first cooling channel, wherein the circumferentially extending second cooling channels are continuous around the circumference of the cooling jacket portion such that each circumferentially extending second cooling channel intersects a plurality of axially extending first cooling channels, wherein the housing is a first housing, wherein the generator system is a first generator system, wherein the first housing is connected to a gear housing such that the first generator system is operatively connected to a permanent magnet generator located inside the gear housing, The first generator system is connected to the permanent magnet generator via a first output shaft, using only a single bearing assembly mounted to the first housing.

14. The device according to claim 13, characterized in that The outer shell includes another cooling channel having a width greater than the plurality of cooling channels as part of the cooling jacket, and the another cooling channel is three-dimensionally printed together with the outer shell.

15. The device according to claim 14, characterized in that The device further includes a three-dimensionally printed second housing, the second housing including another cooling jacket portion, the other cooling jacket portion including one or more cooling channels, and being an integral part of the side wall of the second housing.

16. The device according to claim 15, characterized in that The apparatus further comprises a second generator system, the second generator system comprising: a second main stator, the second main stator being positioned in the second housing; a second main rotor positioned within a cavity of the main stator; a second exciter stator positioned within the second housing; and a second exciter rotor positioned within a cavity of the exciter stator; The second housing is connected to the gear housing such that the second generator system is operably connected to the permanent magnet generator located inside the gear housing.

17. The device according to claim 16, characterized in that The second generator system is connected to the permanent magnet generator via a second output shaft, using only a single bearing assembly mounted to the second housing.

18. The device according to claim 16, characterized in that The second housing includes a further cooling channel that is larger than the one or more cooling channels that are part of the further cooling jacket of the second housing, and the further cooling channel is three-dimensionally printed together with the second housing.

19. The device according to claim 13, characterized in that The cross-sectional shapes of the axially extending first cooling channel and the circumferentially extending second cooling channel are rectangular.

20. The apparatus according to claim 13, wherein The circumferentially extending second cooling channel extends circumferentially in a spiral shape.

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