Direct drive electric variable speed turbine fan

Abstract

The present disclosure provides a direct drive electric variable speed turbofan comprising: a first magnetic gearbox assembly connected to a fan of a turbofan engine; a second magnetic gearbox assembly connected to a spool of the turbofan engine; and a speed controller configured to adjust a rotational speed of the fan based on a rotational speed of the spool by selectively coupling and decoupling the first magnetic gearbox assembly with the second magnetic gearbox assembly. In various aspects, the first magnetic gearbox assembly or the second magnetic gearbox assembly comprises a permanent magnet array, while a different one of the first magnetic gearbox assembly or the second magnetic gearbox assembly comprises a rotor winding separated from the permanent magnet array by an air gap; and the speed controller is configured to selectively couple and decouple the first magnetic gearbox assembly and the second magnetic gearbox assembly with each other via control of switches in a winding circuit having the rotor winding.

Description

Technical Field

[0001] The present disclosure generally relates to turbofan engines. More specifically, the present disclosure relates to turbofan engines configured to convert mechanical rotational energy from a turbine-driven spool into mechanical rotational energy in a fan via electromagnetic force. Background Technology

[0002] In a turbofan engine, the high-pressure exhaust gas produced by burning fuel in the combustion chamber rotates various turbines. These turbines, in turn, rotate a spool. The spool is then connected to various compressors that feed air into the combustion chamber and fans that push the air through a bypass chamber surrounding the turbines. The air driven by the fans provides a portion of the power to the turbofan engine (typically a large portion in "high bypass" turbofan engines).

[0003] During the operation of a conventional turbofan engine, a mechanical gear drive arrangement (e.g., planetary gears) allows the fan to rotate at a different speed than the spool that provides rotational force to the fan. These mechanical gear drives are often heavy and bulky and prone to mechanical stresses (e.g., wear, material fatigue, lubricant leakage, etc.), requiring frequent inspection and maintenance to keep them in good working order. Furthermore, in addition to the mechanical stresses between the components themselves, mechanical gear drives can contribute to noise and vibration in turbofan engines due to the physical contact between the parts. Summary of the Invention

[0004] In one aspect, this disclosure provides a system comprising: a first magnetic gearbox assembly connected to a fan of a turbofan engine; a second magnetic gearbox assembly connected to a reel of the turbofan engine; and a speed controller configured to adjust the fan speed based on the reel speed by selectively engaging and disengaging the first magnetic gearbox assembly and the second magnetic gearbox assembly.

[0005] In one aspect, in conjunction with any of the exemplary systems described above or below, the first magnetic gearbox assembly includes an array of permanent magnets; the second magnetic gearbox assembly includes a rotor winding separated from the permanent magnet array by an air gap; and the speed controller is configured to selectively engage and disengage the first magnetic gearbox assembly from the second magnetic gearbox assembly via closing and opening a switch in a winding circuit having the rotor winding.

[0006] In one aspect, in conjunction with any of the exemplary systems described above or below, the second magnetic gearbox assembly includes an array of permanent magnets; the first magnetic gearbox assembly includes a rotor winding separated from the permanent magnet array by an air gap; and the speed controller is selectively configured to selectively engage and disengage the first magnetic gearbox assembly from the second magnetic gearbox assembly via closing and opening switches in the winding circuit having the rotor winding.

[0007] In one respect, in conjunction with any of the exemplary systems described above or below, the first magnetic gearbox assembly is coaxially positioned within a cavity defined by the second magnetic gearbox assembly.

[0008] In one respect, in conjunction with any of the exemplary systems described above or below, the second magnetic gearbox assembly is coaxially positioned within a cavity defined by the first magnetic gearbox assembly.

[0009] In one respect, in conjunction with any of the exemplary systems above or below, the first magnetic gearbox assembly and the second magnetic gearbox assembly are electromagnetically linked via a coaxial magnetic field.

[0010] In one aspect, in conjunction with any of the exemplary systems described above or below, the speed controller is configured to disconnect the first magnetic gearbox assembly from the second magnetic gearbox assembly at least by turning off a switch via a switch driver powered by current generated by the rotation of the first magnetic gearbox assembly relative to the second magnetic gearbox assembly.

[0011] In one respect, in conjunction with any of the exemplary systems described above or below, the speed controller is configured to adjust the fan speed based on the difference between a reference speed of the fan and a measured speed of the fan.

[0012] In one aspect, in conjunction with any of the exemplary systems described above or below, the speed controller also includes a speed sensor, which includes at least one of the following: a Hall effect sensor; an inductive sensor; and an opto-isolator sensor.

[0013] In one aspect, in conjunction with any of the exemplary systems described above or below, the system also includes an engine thrust controller configured to transmit a reference speed to a speed controller via contactless communication.

[0014] In one aspect, this disclosure provides a turbofan engine comprising: a fan; a turbine housing including an intake port at an upstream end, a compression section downstream of the intake port, a combustion section downstream of the compression section, a turbine section downstream of the combustion section, and an exhaust port at a downstream end; a first spool connected to a first compressor of the compression section and connected to a first turbine of the turbine section; an electric gearbox located upstream of the turbine housing, the electric gearbox including a first magnetic gearbox assembly connected to the fan and a second magnetic gearbox assembly connected to the first spool, wherein the electric gearbox is configured to transmit rotational energy through an air gap between the first magnetic gearbox assembly and the second magnetic gearbox assembly from the first spool rotating at a second rotational speed to the fan rotating at a first rotational speed; and a speed controller connected to the electric gearbox and configured to selectively engage and disengage the first magnetic gearbox assembly and the second magnetic gearbox assembly through the air gap to adjust the first rotational speed to a variable fan reference speed while maintaining the second rotational speed at a constant rate.

[0015] In one aspect, in conjunction with any of the exemplary turbofan engines described above or below, the first magnetic gearbox assembly includes an array of permanent magnets, and the second magnetic gearbox assembly includes a winding circuit defining rotor windings; and the speed controller is configured to reduce the duty cycle of the switches in the winding circuit to reduce the first speed relative to the second speed.

[0016] In one aspect, in conjunction with any of the exemplary turbofan engines described above or below, the first magnetic gearbox assembly includes a winding circuit defining a rotor winding, the second magnetic gearbox assembly includes an array of permanent magnets, and the speed controller is configured to reduce the duty cycle of the switches in the winding circuit to reduce the first speed relative to the second speed.

[0017] In one respect, in conjunction with any of the exemplary turbofan engines described above or below, the air gap is one of the following: coaxial with the first spool and defined by disposing the second magnetic gearbox assembly in a first cavity defined by the first magnetic gearbox assembly; coaxial with the first spool and defined by disposing the first magnetic gearbox assembly in a second cavity defined by the second magnetic gearbox assembly; and perpendicular to the axis of rotation of the first spool and defined by disposing the first magnetic gearbox assembly parallel to the second magnetic gearbox assembly.

[0018] In one aspect, this disclosure provides a method comprising: rotating a spool in a turbofan engine at a first rotational speed; transferring rotational energy from the spool to a fan in the turbofan engine via an electric gearbox; adjusting a portion of the rotational energy transferred to the fan based on the duty cycle of a switch in a winding circuit of the electric gearbox; and rotating the fan at a second rotational speed based on the duty cycle.

[0019] In one aspect, in conjunction with any of the above or below exemplary methods, an electric transmission includes: a first magnetic transmission assembly including a winding circuit and a switch, wherein the first magnetic transmission assembly is coupled to a reel; and a second magnetic transmission assembly including an array of permanent magnets, wherein the second magnetic transmission assembly is coupled to a fan and separated from the first magnetic transmission assembly via an air gap.

[0020] In one aspect, in conjunction with any of the exemplary methods described above or below, an electric transmission includes: a first magnetic transmission assembly including a winding circuit and a switch, wherein the first magnetic transmission assembly is coupled to a fan; and a second magnetic transmission assembly including an array of permanent magnets, wherein the second magnetic transmission assembly is coupled to a reel and separated from the first magnetic transmission assembly via an air gap.

[0021] In one aspect, in conjunction with any of the exemplary methods described above or below, the method further includes: measuring a second rotational speed; and in response to the second rotational speed not matching a threshold of the fan's reference speed, adjusting the duty cycle of the switch while continuing to rotate the reel at a first rotational speed.

[0022] In one aspect, this disclosure provides a method comprising: attaching a first magnetic gearbox assembly to a first reel of a turbofan engine, the first magnetic gearbox assembly including a winding circuit defining a rotor winding and having a selectively configurable switch and a first of an array of permanent magnets; attaching a second magnetic gearbox assembly to a fan of the turbofan engine, the second magnetic gearbox assembly including a winding circuit and a second of a permanent magnet array different from the first, wherein the first magnetic gearbox assembly and the second magnetic gearbox assembly define an air gap therebetween; attaching a speed sensor to the turbofan engine to monitor the fan's rotational speed; and coupling a speed controller to the speed sensor and the winding circuit, wherein the speed controller is configured to adjust the duty cycle of the selectively configurable switch based on the difference between the fan's rotational speed and a reference speed of the fan.

[0023] In one aspect, in conjunction with any of the exemplary methods described above or below, the attachment of the first magnetic gearbox assembly and the attachment of the second magnetic gearbox assembly are defined by one of the following: the first magnetic gearbox assembly is disposed in a first cavity defined by the second magnetic gearbox assembly, wherein the air gap is coaxial with the first spool; the second magnetic gearbox assembly is disposed in a second cavity defined by the first magnetic gearbox assembly, wherein the air gap is coaxial with the first spool; and the first magnetic gearbox assembly is disposed parallel to the second magnetic gearbox assembly, wherein the air gap is perpendicular to the axis of rotation of the first spool.

[0024] In one aspect, this disclosure provides a processing system comprising: a memory including computer-executable instructions; and a processor configured to execute the computer-executable instructions and cause the processing system to perform any of the methods described above.

[0025] In one aspect, this disclosure provides a non-transitory computer-readable medium comprising computer-executable instructions that, when executed by a processor of a processing system, cause the processing system to perform any of the methods described above.

[0026] In one aspect, this disclosure provides a computer program product embodied on a computer-readable storage medium, the computer-readable storage medium including code for performing any of the methods described above. Attached Figure Description

[0027] To gain a more detailed understanding of the features described above, a more specific description can be made by referring to exemplary aspects, some of which are shown in the accompanying drawings.

[0028] Figures 1A to 1C A cross-sectional view of a turbofan engine including an electric transmission according to various aspects of this disclosure is shown.

[0029] Figures 2A to 2C Cross sections of various configurations of the electric transmission according to various aspects of this disclosure are shown.

[0030] Figures 3A to 3C The diagram shows the winding circuit inside a permanent magnet array for an electric transmission according to various aspects of this disclosure.

[0031] Figures 4A to 4C The diagram shows the external winding circuit of a permanent magnet array for an electric transmission according to various aspects of this disclosure.

[0032] Figures 5A to 5C A speed controller for an electric transmission is shown according to various aspects of this disclosure.

[0033] Figure 6 This is a flowchart of a method for controlling a turbofan engine with an electric gearbox, according to various aspects of this disclosure.

[0034] Figure 7 This is a flowchart of a method for manufacturing a turbofan engine with an electric gearbox according to various aspects of this disclosure.

[0035] Figure 8A and Figure 8B The arrangement of components for a generator according to various aspects of this disclosure is shown. Detailed Implementation

[0036] This disclosure provides a controllable electric variable-speed turbofan engine that replaces the mechanical gear drive arrangement between the shaft and the fan with electromagnetic coupling. Electromagnetic coupling allows the transmission of rotational energy / torque without physical contact between the gear components, which reduces the weight and size of the turbofan engine assembly and the maintenance requirements of the gear drive arrangement compared to a mechanical gear drive arrangement.

[0037] A speed controller is provided that adjusts the effective "gear ratio" between the reel and the fan, enabling more continuous control of the fan speed (e.g., revolutions per minute (RPM)). In other words, the fan speed can be controlled independently of the reel speed, allowing the fan to be driven at a variable rate, while driving the reel at a relatively constant rate is optimized for various performance characteristics of the turbofan engine. Advantageously, the electromagnetic gearbox and speed controller of this disclosure can provide greater fuel efficiency over a wider range of thrust and speed for the turbofan engine compared to that offered by conventional static variable-speed turbofan engines.

[0038] While the examples provided in this disclosure primarily illustrate aircraft turbofans, the electric geared drive arrangements described herein can be used in conjunction with turbofan engines in a variety of other vehicles.

[0039] Figures 1A to 1C A cross-sectional view of a turbofan engine 100 (turbofan engine 100A and turbofan engine 100B, respectively) including an electric transmission 110 according to various aspects of this disclosure is shown. The turbofan engine 100 includes a turbine housing 120 defining an intake 121 at an upstream end, a compression section 122 downstream of the intake 121, a combustion section 123 downstream of the compression section 122, a turbine section 124 downstream of the combustion section 123, and an exhaust port 125 at a downstream end. In various aspects, the turbine housing 120 is included inside an engine nacelle 130 (also referred to as a casing), and a bypass flow chamber 131 is defined between an outer surface of the turbine housing 120 and an inner surface of the engine nacelle 130. The fan 150 is located within the engine nacelle 130 upstream of the air intake 121 of the turbine housing 120, and during operation the fan rotates to push air inward to the air intake 121 of the turbine housing 120 and through the bypass flow chamber 131, thereby providing intake volume and thrust.

[0040] Figure 1A A turbofan engine 100 is shown, which includes a first reel 160A (generally, the reel or shaft 160 or collectively referred to as the shaft assembly) and a second reel 160B. Figure 1BA turbofan engine is shown, which includes a first reel 160A, a second reel 160B, and a third reel 160C, but in different aspects, the turbofan engine 100 may include one, two, three, or more reels 160.

[0041] In the depicted embodiment, each shaft 160 extends coaxially with the other shafts 160, and each shaft, during operation, is subjected to high-pressure exhaust gas injection... Figure 1A Turbine 180A-B (generally, turbine 180) or according to Figure 1B The turbines 180A-C rotate at different speeds relative to each other, which in turn drive them at different speeds via the connected reel 160. Figure 1A The associated compressors 170A-B (generally, compressor 170) or according to Figure 1B The compressors 170A-C. For example, the first spool 160A rotates (due to the force applied by the first turbine 180A) to drive the first compressor 170A to rotate at a first speed, while the second spool 160B rotates (due to the force applied by the second turbine 180B) to drive the second compressor 170B to rotate at a second speed. Although not shown, various bearings or low-friction surfaces may be located between the shafts 160 to improve the rotational characteristics of the shafts 160 (e.g., reduce friction).

[0042] Compressor 170 is disposed in compression section 122 of turbine housing 120, and each compressor may include a plurality of fan blades arranged in one or more rows. Turbine 180 is disposed in turbine section 124 of turbine housing 120, and each turbine may include a plurality of turbine blades arranged in one or more rows.

[0043] As shown in the figure, the first reel 160A is the low-pressure shaft relative to the high-pressure shaft of the second reel 160B. Therefore, the first compressor 170A is located upstream of the second compressor 170B and rotates at a lower speed than the second compressor 170B during operation of the turbofan engine 100. Furthermore, the first turbine 180A is located downstream of the second turbine 180B and rotates at a lower speed than the second turbine 180B during operation of the turbofan engine 100. Similarly, see... Figure 1B The second compressor 170B is located upstream of the third compressor 170C and rotates at a lower speed than the third compressor 170C during operation of the turbofan engine 100. Furthermore, the second turbine 180B is located downstream of the third turbine 180C and rotates at a lower speed than the third turbine 180C during operation of the turbofan engine 100.

[0044] Rotation of the low-pressure first spool 160A is transmitted to the fan 150 via an electric gearbox 110. As it rotates, the fan 150 forces air through the bypass flow chamber 131 of the turbofan engine 100 to power (e.g., thrust) a vehicle using the turbofan engine 100. The fan 150 includes a plurality of fan blades 151 extending from a central hub 152, and the radius of the fan is generally larger than the corresponding blades of the compressor 170 (and turbine 180) in the turbofan engine 100. Thus, if rotating at the same angular velocity or rotational speed (e.g., revolutions per minute) as the compressor 170, the fan 150 will experience higher speeds (and mechanical stresses) at the distal ends of the fan blades 151 than the blades of the compressor 170 and turbine 180. For example, the tips of the blades of compressor 170 (and turbine 180) can travel at subsonic speeds, but the tips of the fan 150, which rotates with the subsonic compressor 170 (and turbine 180), can travel at supersonic speeds due to the larger radius of the fan 150. This can cause noise and vibration problems (in addition to mechanical stress) when the tips of the fan blades 151 break the sound barrier.

[0045] about Figures 2A to 2C , Figures 3A to 3C and Figures 4A to 4C The electric gearbox 110, described in more detail, connects the first spool 160A to the hub 152 of the fan 150 and allows the first spool 160A (and the associated first compressor 170A) to rotate at one speed, and allows the fan 150 to rotate at an independent speed. Independent speeds may include situations where the fan 150 rotates faster, slower, or at the same speed as the first spool 160A. In some aspects, the operator may also cause the speeds of the fan 150 and the first spool 160A to change relative to each other (e.g., accelerate or decelerate the fan 150).

[0046] The electric gearbox 110 uses magnetic coupling components as a gear transmission system, rather than physically interlocked gears, to electromagnetically couple the first spool 160A to the fan 150, so that the portions of the electric gearbox 110 physically connected to the first spool 160A and the fan 150 do not physically contact each other. Instead, a controllable electromagnetic field selectively connects the first spool 160A and the fan 150 in an air gap. The operator controls whether the winding circuit is open or closed, thereby selectively engaging and disengaging the components of the electric gearbox 110 to set the effective gear ratio based on the duty cycle of the winding circuit. In various aspects, control signals can be transmitted to the electric gearbox 110, thereby changing the duty cycle and the ratio between the fan speed and the shaft speed to control the fan speed.

[0047] Therefore, the electric transmission 110 is configured to transfer rotational energy from the spool 160 to the fan 150. In some aspects, the electric transmission 110 is configured to maintain a static gear ratio, or to be controlled via shaft speed without further control signal input. The electricity that generates these electromagnetic fields can be supplied by the power distribution bus 145 or other power transmission mechanisms for the vehicle in which the turbofan engine 100 is located (e.g., via transmission cable 140 or wireless resonant power transmitters) (such as...). Figure 1A and 1B Supply is made via either a generator 190 (such as a reel) connected between the two reels 160. Figure 1C To supply, this will be about Figure 8A and Figure 8B Let's discuss this in more detail. In some aspects of using the generator 190, the power distribution bus 145 and / or transmission cable 140 can be omitted.

[0048] The electric gearbox 110 thus allows the reel 160 to rotate at a constant rate and the fan 150 to rotate at different rates (constant or based on a variable fan reference speed) by selectively engaging and disengaging the fan 150 from the first reel 160A.

[0049] In some aspects, such as in Figure 1C In this configuration, a generator 190 is positioned at the interface between the first reel 160A and the second reel 160B (and / or the interface between the second reel 160B and the third reel 160C) to extract electrical energy based on the different rotational speeds of the reels 160. By attaching components of the generator 190 to two different reels (e.g., 160A and 160B) or to two different compressors (e.g., 170A and 170B) at the corresponding interfaces between them, the generator 190 can convert rotational energy into electrical energy based on differential rotational speeds via a series of induced magnetic fields. This electrical energy can then be transferred to various systems inside and outside the turbofan engine 100 without requiring physical contact between the generator components rotating at different rates. The generator 190 utilizes the different rotational speeds of the compressors 170 attached to different shafts 160 to rotate the components relative to each other using the operational rotation of the components of the turbofan engine 100. Figure 8A and Figure 8B The construction of generator 190 will be discussed in more detail.

[0050] Figures 2A to 2CCross sections of various configurations of the electric transmission 110 according to various aspects of this disclosure are shown. As will be understood, the electric transmission 110 may include a housing or other cover to protect internal components from debris, reduce air resistance, etc., mounting hardware for securing the electric transmission 110 to the fan 150 and / or the spool 160, etc. For clarity of discussion of electromagnetic components and their operation, such mechanical features have been omitted from the figures.

[0051] exist Figures 2A to 2C In each configuration shown, a first magnetic gearbox assembly 210A (overall, magnetic gearbox assembly 210) is connected to a fan 150, and a second magnetic gearbox assembly 210B is connected to a first reel 160A. (The remaining text appears to be a fragment and requires further context for accurate translation.) Figures 3A to 3C and Figures 4A to 4C In more detail, one of the magnetic gearbox assemblies 210 includes an array of permanent magnets, and another magnetic gearbox assembly 210 includes a winding circuit with rotor windings (in... Figures 3A to 3C or Figures 4A to 4C (Shown in more detail below). The magnetic gearbox assembly 210 is part of the electric gearbox 110 and is separated from each other by an air gap 230, which is selectively bridged by electromagnetic fields between the magnetic gearbox assemblies 210.

[0052] exist Figure 2A In this configuration, a second magnetic gearbox assembly 210B defines a first cavity 240A (generally, cavity 240), within which the first magnetic gearbox assembly 210A is positioned. The first cavity 240A is coaxial with the reel 160 such that the first magnetic gearbox assembly 210A and the second magnetic gearbox assembly 210B cause the magnetic gearbox assembly 210 to rotate about the shared axis of rotation 220 at different points along its length, thereby avoiding the track of the other magnetic gearbox assembly 210 (i.e., avoiding physical contact).

[0053] exist Figure 2B In this configuration, a first magnetic gearbox assembly 210A defines a second cavity 240B, within which a second magnetic gearbox assembly 210B is positioned. The second cavity 240B is coaxial with the reel 160, such that the first magnetic gearbox assembly 210A and the second magnetic gearbox assembly 210B cause the magnetic gearbox assembly 210 to rotate about the shared axis of rotation 220 at different points along its length, thereby avoiding the track of the other magnetic gearbox assembly 210 (i.e., avoiding physical contact).

[0054] exist Figure 2CIn this configuration, a first magnetic gearbox assembly 210A and a second magnetic gearbox assembly 210B are positioned facing each other, with an air gap 230 between their physical components. The first magnetic gearbox assembly 210A and the second magnetic gearbox assembly 210B are coaxially aligned with each other, coaxially aligned with the hub 152 and the first reel 160A, and arranged facing each other such that the magnetic field between the magnetic gearbox assemblies 210 is projected coaxially to connect the magnetic gearbox assemblies 210. The first magnetic gearbox assembly 210A is arranged parallel to the second magnetic gearbox assembly 210B such that the air gap 230 is perpendicular to the axis of rotation 220 for the reel 160, defining a planar air gap 240C (rather than a cavity where one magnetic gearbox assembly 210 surrounds the other), on which the magnetic gearbox assemblies 210 are selectively linked via a coaxial magnetic field.

[0055] For ease of identification and differentiation, it has been shown Figures 2A to 2C The relative dimensions and positions of the electromagnetic coupling components are determined. However, in various aspects, the relative dimensions, shapes, and orientations of these components can be varied based on the physical characteristics of the turbofan engine 100 in which these components are mounted (e.g., length, thickness, circumference, clearance distance, rotational torque, speed, operating temperature, etc.), the desired power transmission characteristics for the extracted rotational energy (e.g., gear ratio, field strength, relative speed), etc. The lengths of the components along the axis of shaft 160, determined based on the torque and / or rated power requirements of the vehicle from the turbofan engine 100, and the relative dimensions and distances of the individual components are sized to optimize the torque generation and speed of the turbofan engine 100 and the power transmission efficiency in the electric gearbox 110 within the physical constraints of the turbofan engine 100. Therefore, Figures 2A to 2C The purpose is to demonstrate the concept of operation, and not necessarily the specific implementation method. It can be modified based on power requirements, thrust requirements, the specific fuel consumption of the turbofan engine 100, and the material properties of each component, to name just a few considerations.

[0056] Figures 3A to 3C and Figures 4A to 4C Various arrangements of the first magnetic gearbox assembly 210A relative to the second magnetic gearbox assembly 210B are shown according to various aspects of this disclosure. Figures 3A to 3C The diagram shows a winding circuit 310 within the permanent magnet array 340, including a rotor winding 330 and a switch 320. Figures 4A to 4C The winding circuit 310 outside the permanent magnet array 340 is shown. Although shown using an array with a pair of magnetic poles (i.e., a north pole (N) and a south pole (S)), in other respects, the rotor winding 330 and the permanent magnet array 340 may include additional magnetic pole pairs.

[0057] Depending on the configuration of the first magnetic gearbox assembly 210A relative to the second magnetic gearbox assembly 210B (according to...) Figures 2A to 2C The first of the winding circuit 310 and the permanent magnet array 340 is included in the first magnetic gearbox assembly 210A, and the second of the winding circuit 310 and the permanent magnet array 340 is included in the second magnetic gearbox assembly 210B. For example, when the second magnetic gearbox assembly 210B surrounds the first magnetic gearbox assembly 210A (such as...), Figure 2A In the case of (the second magnetic gearbox assembly 210B), the second magnetic gearbox assembly 210B may include a winding circuit 310 (such as...). Figures 4A to 4C (middle) or permanent magnet array 340 (e.g.) Figures 3A to 3C middle).

[0058] Figures 3A to 3C and Figures 4A to 4C Shown in a plane perpendicular to the axis of rotation 220 of the reel, and the internal elements (i.e., Figures 3A to 3C The winding circuit 310 or Figures 4A to 4C The rotational speed of the permanent magnet array 340 in the figure is shown as ω. i external components (i.e., Figures 4A to 4C The winding circuit 310 or Figures 3A to 3C The rotational speed of the permanent magnet array 340 in the figure is shown as ω. e When switch 320 is closed, thus completing the circuit including rotor winding 330, the rotation of permanent magnet array 340 relative to rotor winding 330 induces a current in winding circuit 310, which generates a magnetic field in rotor winding 330. The magnetic field of permanent magnet array 340 and winding circuit 310 interact, causing rotational force (e.g., torque) to be transmitted from spool 160 to fan 150.

[0059] Figure 3A and Figure 4A The corresponding winding circuit 310 and permanent magnet array 340 are shown in a neutral position, wherein the corresponding winding circuit 310 and permanent magnet array 340 are not offset from each other. However, when these components rotate due to the force transmitted from the rotation of the spool 160, an external component can cause the external component to lag or lead by an angle θ. Figure 3B and Figure 4B The corresponding winding circuit 310 and permanent magnet array 340 are shown, wherein the external element lags behind the internal element by an angle θ in the rotational direction. 滞后 (For example, 0 radians < θ) 滞后 <π / 2 radians). Figure 3C and Figure 4C The corresponding winding circuit 310 and permanent magnet array 340 are shown, wherein the external element leads the internal element by an angle θ. 领先 (For example, -π / 2 radians < θ) 领先 <0 radians).

[0060] In one example, a first magnetic gearbox assembly 210A connected to a first reel 160A includes a permanent magnet array 340 and is external to a second magnetic gearbox assembly 210B including a winding circuit 310 (e.g., according to...). Figure 2A and Figures 3A to 3C In this example, when the permanent magnet array 340 lags behind the rotor winding 330, such as in Figure 3B In this process, a current is generated in the rotor winding 330, which in turn generates a rotor magnetic field, which is driven by the permanent magnetic field generated by the permanent magnet array 340. Similarly, when the permanent magnet array 340 leads the rotor winding 330, as in... Figure 3C In this process, a current is generated in the rotor winding 330, which in turn generates a rotor magnetic field pulled by the permanent magnetic field inherent in the permanent magnet array 340. Therefore, rotational energy is transferred from the first spool 160A to the fan 150 without requiring an external power supply to power the rotor winding 330.

[0061] In another example, the first magnetic gearbox assembly 210A connected to the first spool 160A includes a winding circuit 310 and is external to the second magnetic gearbox assembly 210B, which includes a permanent magnet array 340 (e.g., according to...). Figure 2A and Figures 4A to 4C In this example, when the rotor winding 330 lags behind the permanent magnet array 340, as in Figure 4B In this process, a current is generated in the rotor winding 330, which in turn generates a rotor magnetic field. This rotor magnetic field is pulled by the permanent magnetic field generated by the permanent magnet array 340. Similarly, when the rotor winding 330 leads the permanent magnet array 340, as in... Figure 4C In this process, a current is generated in the rotor winding 330, which in turn generates a rotor magnetic field, which is driven by the permanent magnetic field inherent in the permanent magnet array 340. Therefore, rotational energy is transferred from the first reel 160A to the fan 150 without requiring an external power source to power the rotor winding 330.

[0062] A switch 320, included in the winding circuit 310, selectively interconnects one end of the rotor winding 330 with the other to open or close the winding circuit 310. When closed, the switch 320 allows current to flow through the rotor winding 330 to generate a rotor magnetic field, thereby allowing the permanent magnetic field to push or pull the rotor magnetic field. When open, the switch 320 interrupts the current flow through the rotor winding 330, thereby disrupting the generation of the rotor magnetic field and disengaging the magnetic gearbox assembly 210. Depending on the duty cycle of the frequency (and duration) at which the switch 320 opens or closes, the rotor winding 330 may alternate between lagging behind or leading the permanent magnet array 340. Regardless of whether the rotor winding 330 lags behind or leads the permanent magnet array 340, force is transmitted to rotate the fan 150 in the same direction as the first reel 160A.

[0063] The rotational force, which is the torque applied from the first spool 160A to the fan 150, is proportional to the induced current in the rotor winding 330. By controlling the duty cycle of the switch 320, the average value of the induced current over time can be matched with the desired torque. For a given moment of inertia of the rotor R, the dynamic equation for controlling its speed is given according to Equation 1, where J is the moment of inertia of the rotor, T is the torque generated by the interaction of the magnetic fields, and b is the coefficient of friction.

[0064]

[0065] Assuming the friction coefficient b is constant when the rotor is in a steady state (i.e., without acceleration), Equation 2 provides a simplified version of Equation 1.

[0066] T=bω R (2)

[0067] Therefore, the rotational speed of fan 150 is proportional to the average value of the induced current in rotor winding 330 over time.

[0068] Figures 5A to 5C A speed controller 500 for an electric transmission 110 according to various aspects of this disclosure is shown. The speed controller 500 sets the duty cycle of switch 320 to control the induced current in rotor winding 330, thereby controlling the speed of fan 150. The speed controller 500 is located in the same position as winding circuit 310 to control switch 320 included therein. Figure 5A The speed controller 500 is shown located on the fan 150 (i.e., when the first magnetic gearbox assembly 210A includes the winding circuit 310) and receives power from an external power source 580. Figure 5B The speed controller 500 is shown located on the first reel 160A (i.e., when the second magnetic gearbox assembly 210B includes the winding circuit 310) and receives power from an external power source 580. Figure 5CThe aspect in which the speed controller 500 is located on the first spool 160A (i.e., when the second magnetic gearbox assembly 210B includes the winding circuit 310) and receives power from a power source located on the spool 160, is related to... Figure 5A and 5B The opposite of the aspect discussed is receiving power from power source 580, which transmits power to fan 150 through engine compartment and intermediate space.

[0069] The speed controller 500 receives a reference (or target) speed of the fan 150 from the engine thrust controller 510 and a measured speed of the fan 150 from the speed sensor 520. In various aspects, the engine thrust controller 510 is disposed in the engine compartment 130 or in the body of the vehicle controlling the turbofan engine 100, and determines the reference speed of the fan 150 based on the operating conditions of the turbofan engine 100 (e.g., altitude, temperature, number of engines used by the vehicle, etc.) and the desired speed or thrust distribution of the vehicle. In some aspects, the engine thrust controller 510 transmits the reference speed to the speed controller 500 via contactless communication (e.g., light waves or radio waves). Therefore, aspects may include a contactless transmitter 570A paired with a contactless receiver 570B used by the speed controller 500 to receive the reference speed.

[0070] Speed ​​sensor 520 measures the rotational speed of fan 150 and may include several different types of sensors deployed at various locations within turbofan engine 100. In one example, speed sensor 520 includes a Hall effect sensor that measures the magnitude of a magnetic field (e.g., generated by a permanent magnet connected to fan 150) to track the rotational speed of fan 150 based on the frequency of periodic changes in the magnitude of that magnetic field. In another example, speed sensor 520 includes an inductive sensor that measures changes in magnetic flux in a generated or induced magnetic field due to variations in the vicinity of elements of fan 150 (e.g., due to the angle of fan blades 151) or variations in the vicinity of magnetic elements included in the first magnetic gearbox assembly 210A. In yet another example, the speed sensor 520 includes an optical isolator sensor comprising a light emitter and a light receiver to determine the speed of the fan 150 by measuring the frequency at which the emitter and receiver are aligned with each other (e.g., based on the emitted beam between the emitter / receiver located individually on the fan 150 and the reel 160) or based on reflected signals (e.g., from the reflective surface of the fan 150 to a pair of reflective emitters / receivers located on the reel 160).

[0071] Comparator 530 compares the reference speed with the measured speed and provides the difference to control loop 540, such as a proportional-integral-derivative (PID) controller, which uses this difference as feedback on how to adjust the duty cycle of switch 320. For example, when the difference indicates that the measured speed is less than the reference speed, control loop 540 instructs that the duty cycle should be increased so that switch 320 remains closed for a longer period of time, more frequently, or a combination thereof compared to the current duty cycle. In another example, when the difference indicates that the measured speed is greater than the reference speed, control loop 540 instructs that the duty cycle should be decreased so that switch 320 remains open for a longer period of time, more frequently, or a combination thereof compared to the current duty cycle. Thus, in response to the duty cycle indicated by control loop 540, switch 320 is controlled to selectively disengage or selectively engage the magnetic transmission assembly 210 of the electric transmission 110.

[0072] In each aspect, the output from control loop 540 passes through integrator 550 to remove spikes in the output, maintain the output within a specified range, and prevent oscillating changes (e.g., adjusting the size below a threshold or alternating small increases and decreases in the duty cycle within a specified time window) to reduce jitter or strain on fan 150 via rapid or frequent changes in the duty cycle.

[0073] The power switch driver 560 receives an output from the speed controller 500 to implement the duty cycle of the switch 320. In various aspects, the power switch driver 560 is powered via a current generated in the winding circuit 310 or another sensing loop to open and close the switch 320 according to the selected duty cycle. In various aspects, the power switch driver 560 provides power to open a normally closed switch that is closed when power is no longer provided, provides power to close a normally open switch that is open when power is no longer provided, or provides power to change the state of a switch that remains in its current state (i.e., open or closed) when power is no longer provided.

[0074] exist Figure 5A and 5BIn this configuration, power to the electrical components of the speed controller 500 and the power switch driver 560 is received from a power source 580 external to the reel 160 and the electric gearbox 110. In some aspects, this power source may be mounted to the turbine housing 120 or the engine compartment 130. When mounted externally to the electric gearbox 110, power is wirelessly transferred via an air gap from a power transmitter 590A located at the power source 580 to a power receiver 590B located on the reel 160, fan, or electric gearbox 110. In various aspects, depending on the distance between the power transmitter 590A and the power receiver 590B and intermediate objects (including additional power transmitters / receivers for forwarding power between different locations), the power transmitter 590A and the power receiver 590B may include various near-field coupling devices (e.g., inductive or capacitive coupling devices) or far-field coupling devices (e.g., microwave and laser power beamforming devices).

[0075] exist Figure 5C In this configuration, the electrical components of the speed controller 500 and the power switch driver 560 receive power from a power source located at the same location as the reel 160 or the electric gearbox 110. In various aspects, Figure 5C The power source can be a battery or other power storage and release device, such as a supercapacitor. In some respects, Figure 5C The power supply receives input power from the generator 190 connected at the interface between the first spool 160A and the second spool 160B, as per [reference to...]. Figure 1C More detailed description.

[0076] Figure 6 This is a flowchart of a method 600 for controlling a turbofan engine 100 having an electric gearbox 110, according to various aspects of this disclosure.

[0077] Method 600 begins at block 610, wherein the spool 160 of the turbofan engine 100 rotates. In the turbofan engine 100, the operator can rotate the spool 160 by: engaging the turbofan engine 100 to generate thrust for the vehicle; inducing rotational energy on the spool 160 through the combustion of fuel in the combustion chamber; and discharging exhaust gas through the turbine section 124, thereby causing the turbine 180 to rotate the corresponding spool 160. Depending on the number of spools 160 in the turbofan engine 100, the thrust requirements of the vehicle using the turbofan engine 100, the height of the vehicle using the turbofan engine 100, etc., the spools 160 can rotate at various different speeds.

[0078] At frame 620, the electric gearbox 110 transmits rotational energy from the first spool 160A of the turbofan engine 100 to the fan 150. A first magnetic gearbox assembly 210A of the electric gearbox 110 is connected to the first spool 160A and includes one of a winding circuit 310 and a permanent magnet array 340. A second magnetic gearbox assembly 210B of the electric gearbox 110 is connected to the fan 150 and includes one of the winding circuit 310 and the permanent magnet array 340 that is different from the one included in the first magnetic gearbox assembly 210A. The magnetic gearbox assemblies 210 are separated from each other via an air gap 230, but are electromagnetically coupled across the air gap 230 via a rotor magnetic field selectively generated by the rotor winding 330 and a permanent magnetic field selectively generated by the permanent magnet array 340.

[0079] By rotating the first spool 160A (and the connected first magnetic gearbox assembly 210A) at a first rotational speed, a current is induced in the rotor winding 330 of the winding circuit 310 when the switch 320 therein is closed. When a current is induced in the rotor winding 330, the rotor winding 330 generates a rotor magnetic field, which is pushed or pulled by a permanent magnetic field associated with the permanent magnet array 340 in the rotational direction of the first spool 160A. Therefore, the rotation of the first spool 160A can be transmitted via the first magnetic gearbox assembly 210A to the second magnetic gearbox assembly 210B connected to the fan 150, thereby causing the fan 150 to rotate together with the first spool 160A.

[0080] At frame 630, fan 150 rotates at a second speed based on the first speed of the first reel 160A and the duty cycle of switch 320 selected by speed controller 500.

[0081] At box 640, speed controller 500 measures a second rotational speed of fan 150. In various aspects, speed sensor 520 (such as a Hall effect sensor, inductive sensor, opto-isolator sensor, etc.) measures the speed of fan 150, and speed controller 500 compares the measured speed with a reference (or target) speed at which fan 150 has been set to rotate. Speed ​​controller 500 bases its judgment on whether the difference between the reference speed of fan 150 and the measured speed of fan 150 falls outside a threshold range (e.g., Δ(ω...)). 参考 ω 测量 )±ω 参考 The duty cycle of switch 320 is determined by x% (and thus the speed of fan 150 is adjusted).

[0082] At block 650, speed controller 500 adjusts a portion of the rotational energy delivered to fan 150 based on the duty cycle of switch 320 in winding circuit 310 of electric gearbox 110. By increasing the relative amount of time switch 320 is closed, speed controller 500 increases the portion of rotational energy delivered from reel 160 to fan 150, thereby increasing the speed of fan 150. Similarly, by decreasing the relative amount of time switch 320 is closed, speed controller 500 decreases the portion of rotational energy delivered from reel 160 to fan 150, thereby decreasing the speed of fan 150. When the reference speed is greater than the measured speed and outside a threshold, method 600 returns to block 630, where the duty cycle of switch 320 is increased, thereby increasing the speed of fan 150. When the reference speed is less than the measured speed and outside a threshold, method 600 returns to block 630, where the duty cycle of switch 320 is decreased, thereby decreasing the speed of fan 150. Therefore, method 600 can continue to control the speed of fan 150 relative to an updated reference speed, changes in environmental conditions, changes in the rotational speed of reel 160, and combinations thereof.

[0083] Figure 7 This is a flowchart of a method 700 for manufacturing a turbofan engine 100 having an electric gearbox 110, according to various aspects of this disclosure.

[0084] At frame 710, the manufacturer attaches the first magnetic gearbox assembly 210A to the first spool 160A of the turbofan engine 100.

[0085] At frame 720, the manufacturer attaches the second magnetic gearbox assembly 210B to the fan 150 of the turbofan engine 100.

[0086] The first magnetic gearbox assembly 210A includes a first of the winding circuit 310 and the permanent magnet array 340, while the second magnetic gearbox assembly 210B includes a second of the winding circuit 310 and the permanent magnet array 340 that is different from the first one included in the first magnetic gearbox assembly 210A. The first magnetic gearbox assembly 210A and the second magnetic gearbox assembly 210B define an air gap 230 between them, such that the first magnetic gearbox assembly 210A and the second magnetic gearbox assembly 210B do not physically contact each other. Instead, the first magnetic gearbox assembly 210A and the second magnetic gearbox assembly 210B are configured to selectively magnetically contact each other. In various aspects, the first magnetic gearbox assembly 210A is disposed in a first cavity 240A defined by the second magnetic gearbox assembly 210B (according to...). Figure 2AThe second magnetic gearbox assembly 210B is disposed in the second cavity 240B defined by the first magnetic gearbox assembly 210A, or the magnetic gearbox assemblies 210 are arranged parallel to each other to define an air gap 230 perpendicular to the rotation axis 220 of the spool 160 (according to...). Figure 2C ).

[0087] At frame 730, the manufacturer attaches a speed sensor 520 to the fan 150 within the turbofan engine 100 to monitor the rotational speed of the fan 150. The speed sensor 520 may include various types of speed sensing or measuring devices, including but not limited to: Hall effect sensors, inductive sensors, and optical isolators. In various aspects, the speed sensor may include a component attached to one or more of the fan 150, the first reel 160A, the turbine housing 120, the engine nacelle 130, or other components of the turbofan engine 100.

[0088] At frame 740, the manufacturer connects the speed controller 500 to the speed sensor 520 and the winding circuit 310. The speed controller 500 is configured to adjust the duty cycle of the switch 320 included in the winding circuit 310 based on the difference between the rotational speed of the fan 150 measured by the speed sensor 520 and the desired speed of the fan 150 (as indicated by the engine thrust controller 510, which communicates non-contactly with the speed controller 500). The speed controller 500 is located on the fan 150 when the first magnetic gearbox assembly 210A includes the winding circuit 310, or on the first reel 160A when the second magnetic gearbox assembly 210B includes the winding circuit 310.

[0089] Figure 8A A first component arrangement 800A for a generator 190 according to various aspects of this disclosure is shown. A first rotor assembly 810A is connected to a second (high-pressure) compressor 170B, and a second rotor assembly 810B is connected to a first (low-pressure) compressor 170A at an interface between the first compressor 170A and the second compressor 170B. In various aspects, rotor assemblies 810A-B are connected to one or more blades of the associated compressor 170, to a ring / connection point from the blades to the associated spool 160, or to the associated spool 160. Rotor assemblies 810A-B position various electromagnetic components of the generator 190 with known distances and orientations relative to each other, the shaft 160, and the compressor 170.

[0090] exist Figure 8AIn the first rotor assembly 810A, a permanent magnet 820 is included to generate a generator magnetic field 815. The permanent magnet 820 radially emits the generator magnetic field 815 through an air gap defined coaxially with the shaft 160, thereby magnetically connecting the permanent magnet 820 to a generator armature winding 830 included in a second rotor assembly 810B. In various aspects, the permanent magnet 820 may include a plurality of magnets arranged circumferentially around the shaft 160 to emit a plurality of generator magnetic fields 815.

[0091] The second rotor assembly 810B includes a generator armature winding 830, which is arranged concentrically and radially with the permanent magnet 820 or the shaft 160, but not in physical contact with it. The second rotor assembly 810B positions the generator armature winding 830 within a predetermined field strength of the generator magnetic field 815. Therefore, the generator magnetic field 815 radially connects the permanent magnet 820 and the generator armature winding 830.

[0092] Figure 8B A second component arrangement 800B for a generator 190 according to various aspects of this disclosure is shown. A first rotor assembly 810A is connected to a high-pressure second compressor 170B, and a second rotor assembly 810B is connected to a low-pressure first compressor 170A at an interface between the two compressors 170. In various aspects, rotor assemblies 810A-B are connected to one or more blades of the associated compressor 170, to a ring / connection point between the blades and the associated reel 160, or to the associated reel 160. Rotor assemblies 810A-B position various electromagnetic components of the generator 190 with known distances and orientations relative to each other, the shaft 160, and the compressor 170.

[0093] exist Figure 8B In the first rotor assembly 810A, a permanent magnet 820 is included to generate a generator magnetic field 815. The permanent magnet 820 emits the generator magnetic field 815 through an air gap defined in a plane intersecting the axis of rotation of the shaft 160, thereby magnetically connecting the permanent magnet 820 to a generator armature winding 830 included in the second rotor assembly 810B. Although shown as having an air gap defined in a plane orthogonal to the axis of rotation (e.g., for coaxial magnetic connection between the permanent magnet 820 and the generator armature winding 830), in other respects, the air gap may be defined at other angles relative to the shaft 160. In various aspects, the permanent magnet 820 may include a plurality of magnets arranged radially around the shaft 160 to emit a plurality of generator magnetic fields 815.

[0094] The second rotor assembly 810B includes a generator armature winding 830, which is radially arranged about a shaft 160 but not in physical contact with the shaft 160, and is arranged in a planetary configuration with the permanent magnet 820. The relative positions and lengths of the rotor assemblies 810A-B position the generator armature winding 830 within a predetermined field strength of the generator magnetic field 815. Therefore, the generator magnetic field 815 axially connects the permanent magnet 820 and the generator armature winding 830.

[0095] During operation of the turbofan engine 100 in which these components are housed, the rotational force exerted by the turbine 180 causes the compressor 170 and its attached EM components to rotate relative to each other and to the fixed turbine housing 120. Due to the speed difference between the high-pressure compressor 170B and the low-pressure compressor 170A, the generator magnetic field 815 rotates relative to the generator armature winding 830. Therefore, in addition to other components (e.g., as a power source 580), electrical energy is extracted from the rotational force of the shaft 160 and transmitted to power the speed controller 500 of the electric gearbox 110.

[0096] For ease of identification and differentiation, it has been shown Figure 8A and Figure 8B The relative dimensions and positions of the electromagnetic coupling components are determined. However, in various aspects, the relative dimensions, shapes, and orientations of these components can be varied based on the physical properties of the turbofan engine 100 in which these components are mounted (e.g., length, thickness, perimeter, clearance distance, rotational torque and speed, operating temperature), the desired power characteristics of the extracted power (e.g., number of power phases, voltage / current levels), etc. The length of the components along the axis 160 is determined by the torque and / or rated power requirements of the vehicle from the turbofan engine 100, and the relative dimensions and distances of the individual components are sized to optimize the torque generation and speed of the turbofan engine 100 and the power transmission efficiency in the generator 190 within the physical constraints of the turbofan engine 100. Therefore, Figure 8A and 8B The purpose is to demonstrate the concept of operation, and not necessarily a specific implementation. It can be modified based on power requirements, thrust requirements, the specific fuel consumption of the turbofan engine 100, and the material properties of individual components. For example, when radial space along the blade length of the compressor 170 is more readily available, the manufacturer can, according to... Figure 8A The manufacturer may design the permanent magnet 820 and the generator armature winding 830, or, when the axial space between the compressor 170 is more readily available, according to... Figure 8B Design permanent magnet 820 and generator armature winding 830.

[0097] In this disclosure, references are made to various aspects. However, it should be understood that this disclosure is not limited to the aspects specifically described. Rather, any combination of the following features and elements (whether or not they relate to different aspects) is contemplated for practicing and implementing the teachings provided herein. Furthermore, when elements of these aspects are described in the form of “at least one of A and B,” it should be understood that aspects including only element A, only element B, and aspects including both elements A and B are considered. Moreover, while some aspects may achieve advantages over other possible solutions and / or over the prior art, whether a particular advantage is achieved by a given aspect does not limit this disclosure. Therefore, the aspects, features, aspects, and advantages disclosed herein are merely illustrative and should not be considered as elements or limitations of the appended claims unless expressly stated in the claims. Similarly, references to “the invention” should not be construed as a generalization of any inventive subject matter disclosed herein and should not be considered as elements or limitations of the appended claims unless expressly stated in the claims.

[0098] As those skilled in the art will understand, the aspects described herein may be embodied as a system, method, or computer program product. Therefore, the aspects may take the form of a purely hardware aspect, a purely software aspect (including firmware, resident software, microcode, etc.), or a combination of software and hardware aspects, all of which are collectively referred to herein as “circuit,” “module,” or “system.” Furthermore, the aspects described herein may take the form of a computer program product embodied in one or more computer-readable storage media having computer-readable program code embodied thereon.

[0099] Program code embodied on a computer-readable storage medium may be transmitted using any suitable medium, including but not limited to wireless, wired, optical fiber, RF, or any suitable combination thereof.

[0100] Computer program code used to perform the operations of various aspects of this disclosure may be written in any combination of one or more programming languages, including object-oriented programming languages ​​such as Java, Smalltalk, C++, etc., and traditional procedural programming languages ​​such as the "C" programming language or similar programming languages. The program code may execute entirely on the user's computer, partially on the user's computer, as a standalone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In the latter case, the remote computer may be connected to the user's computer via any type of network (including a local area network (LAN) or a wide area network (WAN)) or may be connected to an external computer (e.g., via the Internet through an Internet service provider).

[0101] This document describes aspects of the present disclosure with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to these aspects. It should be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, executable by the processor of the computer or other programmable data processing apparatus, create methods for implementing the functions / actions specified in the blocks of the flowchart illustrations and / or block diagrams.

[0102] These computer program instructions may also be stored in a computer-readable medium that can instruct a computer, other programmable data processing apparatus or other device to operate in a particular manner, such that the instructions stored in the computer-readable medium produce an article of writing that includes instructions that implement the functions / actions specified in the blocks of flowcharts and / or block diagrams.

[0103] Computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable data processing apparatus, or other device to produce a computer-implemented process, such that the instructions that execute on the computer, other programmable data processing apparatus, or other device provide for implementing the process for carrying out the functions / actions specified in the flowchart and / or block diagram (or blocks).

[0104] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various aspects of this disclosure. Each block in a flowchart or block diagram may represent a module, segment, or portion of code, comprising one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than indicated in the figures. For example, depending on the functions involved, two consecutively shown blocks may actually be executed simultaneously, or these blocks may sometimes be executed in reverse order or out of order. It should also be noted that each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, may be implemented using a dedicated hardware-based system that performs the specified function or action, or using a combination of dedicated hardware and computer instructions.

[0105] Terms:

[0106] 1. A system comprising:

[0107] The first magnetic gearbox assembly (210A) is connected to the fan (150) of the turbofan engine (100);

[0108] The second magnetic gearbox assembly (210B) is connected to the reel (160) of the turbofan engine (100); and

[0109] The speed controller (500) is configured to adjust the rotational speed of the fan (150) based on the rotational speed of the reel (160) by selectively engaging and disengaging the first magnetic gearbox assembly (210A) and the second magnetic gearbox assembly (210B).

[0110] 2. The system according to Clause 1, wherein:

[0111] The first magnetic gearbox assembly (210A) includes a permanent magnet array (340);

[0112] The second magnetic gearbox assembly (210B) includes a rotor winding (330) separated from the permanent magnet array (340) by an air gap (230); and

[0113] The speed controller (500) is configured to selectively engage and disengage the first magnetic gearbox assembly (210A) from the second magnetic gearbox assembly (210B) via closing and opening a switch (320) in a winding circuit (310) having the rotor winding (330).

[0114] 3. The system according to clause 1 or 2, wherein:

[0115] The second magnetic gearbox assembly (210B) includes a permanent magnet array (340);

[0116] The first magnetic gearbox assembly (210A) includes a rotor winding (330) separated from the permanent magnet (340) array by an air gap (230); and

[0117] The speed controller (500) is configured to selectively engage and disengage the first magnetic gearbox assembly (210A) from the second magnetic gearbox assembly (210B) via closing and opening a switch (320) in a winding circuit (310) having the rotor winding (330).

[0118] 4. The system according to any one of Clauses 1 to 3, wherein the first magnetic gearbox assembly (210A) is coaxially positioned within a cavity (240) defined by the second magnetic gearbox assembly (210B).

[0119] 5. The system according to any one of the clauses 1-4, wherein the second magnetic gearbox assembly (210B) is coaxially positioned within a cavity (240) defined by the first magnetic gearbox assembly (210A).

[0120] 6. The system according to any one of the clauses 1-5, wherein the first magnetic gearbox assembly (210A) and the second magnetic gearbox assembly (210B) are electromagnetically connected via a coaxial magnetic field.

[0121] 7. The system according to any one of Clauses 1-6, wherein the speed controller (500) is configured to disconnect the first magnetic gearbox assembly (210A) from the second magnetic gearbox assembly (210B) at least by disconnecting the switch (320) via a switch driver (560), the switch driver being powered by current generated by the rotation of the first magnetic gearbox assembly (210A) relative to the second magnetic gearbox assembly (210B).

[0122] 8. The system according to any one of the clauses 1 to 7, wherein the speed controller (500) is configured to adjust the rotational speed of the fan (150) based on the difference between a reference speed of the fan (150) and a measured speed of the fan (150).

[0123] 9. The system according to any one of clauses 1 to 8, wherein the speed controller (500) further includes a speed sensor (520), the speed sensor (520) comprising at least one of the following:

[0124] Hall effect sensor;

[0125] Inductive sensors; and

[0126] Optical isolator sensor.

[0127] 10. The system according to any one of the clauses 1 to 9 further includes: an engine thrust controller (510) configured to transmit a reference speed to a speed controller (500) via contactless communication.

[0128] 11. A turbofan engine (100), comprising:

[0129] Fan (150);

[0130] The turbine housing (120) includes: an air inlet (121) located at the upstream end; a compression section (122) located downstream of the air inlet (121); a combustion section (123) located downstream of the compression section (122); a turbine section (124) located downstream of the combustion section (123); and an exhaust port (125) located at the downstream end.

[0131] The first reel (160A) is connected to the first compressor (170A) of the compression section (122) and to the first turbine (180A) of the turbine section (124);

[0132] An electric gearbox (110), located upstream of the turbine housing (120), includes a first magnetic gearbox assembly (210A) connected to a fan (150) and a second magnetic gearbox assembly (210B) connected to a first reel (160A). The electric gearbox (110) is configured to transmit rotational energy from the first reel (160A) rotating at a second rotational speed to the fan (150) rotating at a first rotational speed via an air gap (230) between the first magnetic gearbox assembly (210A) and the second magnetic gearbox assembly (210B).

[0133] A speed controller (500) is coupled to an electric gearbox (110) and configured to selectively engage and disengage a first magnetic gearbox assembly (210A) and a second magnetic gearbox assembly (210B) over an air gap (230) to adjust a first speed to a variable fan reference speed while maintaining a second speed at a constant rate.

[0134] 12. The turbofan engine (100) as described in Clause 11, wherein:

[0135] The first magnetic gearbox assembly (210A) includes a permanent magnet array (340), and the second magnetic gearbox assembly (210B) includes a winding circuit (310) defining a rotor winding (330); and

[0136] The speed controller (500) is configured to reduce the duty cycle of the switch (320) in the winding circuit (310) to reduce the first speed relative to the second speed.

[0137] 13. The turbofan engine (100) as described in clause 11 or 12, wherein:

[0138] The first magnetic gearbox assembly (210A) includes a winding circuit (310) defining a rotor winding (330), and the second magnetic gearbox assembly (210B) includes a permanent magnet array (340); and

[0139] The speed controller (500) is configured to reduce the duty cycle of the switch (320) in the winding circuit (310) to reduce the first speed relative to the second speed.

[0140] 14. The turbofan engine (100) according to any one of clauses 11-13, wherein the air gap (230) is one of the following:

[0141] It is coaxial with the first spool (160A) and is defined by placing the second magnetic gearbox assembly (210B) in the first cavity (240A) defined by the first magnetic gearbox assembly (210A);

[0142] Coaxial with the first spool (160A) and defined by placing the first magnetic gearbox assembly (210A) within a second cavity (240B) defined by the second magnetic gearbox assembly (210B); and

[0143] The rotation axis (220) is perpendicular to the first spool (160A) and is defined by the first magnetic gearbox assembly (210A) being arranged parallel to the second magnetic gearbox assembly (210B).

[0144] 15. A method (600) comprising:

[0145] The spool (160) in the turbofan engine (100) is rotated (610) at a first rotational speed;

[0146] Rotational energy is transmitted (620) from the spool (160) via the electric gearbox (110) to the fan (150) in the turbofan engine (100);

[0147] A portion of the rotational energy transmitted to the fan (150) is based on the duty cycle adjustment (650) of the switch (320) in the winding circuit (310) of the electric gearbox (110); and

[0148] The fan (150) rotates at a second speed (630) based on the duty cycle.

[0149] 16. The method (600) according to Clause 15, wherein the electric transmission (110) comprises:

[0150] A first magnetic gearbox assembly (210A) includes a winding circuit (310) and a switch (320), wherein the first magnetic gearbox assembly (210A) is coupled to a reel (160); and

[0151] The second magnetic gearbox assembly (210B) includes a permanent magnet array (340), wherein the second magnetic gearbox assembly (210B) is coupled to the fan (150) and separated from the first magnetic gearbox assembly (210A) via an air gap (230).

[0152] 17. The method (600) according to clause 15 or 16, wherein the electric transmission comprises:

[0153] A first magnetic gearbox assembly (210A) includes a winding circuit (310) and a switch (320), wherein the first magnetic gearbox assembly (210A) is coupled to a fan (150); and

[0154] The second magnetic gearbox assembly (210B) includes a permanent magnet array (340), wherein the second magnetic gearbox assembly (210B) is coupled to the reel (160) and separated from the first magnetic gearbox assembly via an air gap.

[0155] 18. The method (600) described under any of clauses 15-17 further includes:

[0156] Measure the second rotational speed; and

[0157] In response to the mismatch between the second rotation speed and the threshold of the reference speed of the fan (150), the duty cycle of the switch (320) is adjusted while the reel (160) continues to rotate at the first rotation speed.

[0158] 19. A method (700) comprising:

[0159] A first magnetic gearbox assembly (210A) comprising a winding circuit (310) and a permanent magnet array (340) is attached (710) to a first reel (160A) of a turbofan engine (100), the winding circuit defining a rotor winding (330) and having a selectively configurable switch (320).

[0160] The second magnetic gearbox assembly (210B) is attached (720) to the fan (150) of the turbofan engine (100). The second magnetic gearbox assembly (210B) includes a winding circuit (310) and a second one of a permanent magnet array (340) that is different from the first one. The first magnetic gearbox assembly (210A) and the second magnetic gearbox assembly (210B) define an air gap (230) therebetween.

[0161] A speed sensor (520) is attached (730) to the turbofan engine (100) to monitor the rotational speed of the fan (150); and

[0162] The speed controller (500) is connected (740) to the speed sensor (520) and the winding circuit (310), wherein the speed controller (500) is configured to adjust the duty cycle of the selectively configurable switch (320) based on the difference between the rotational speed of the fan (150) and a reference speed of the fan (150).

[0163] 20. The method (700) according to Clause 19, wherein the attached first magnetic gearbox assembly (210A) and the attached second magnetic gearbox assembly (210B) define the air gap (230) by one of the following:

[0164] The first magnetic gearbox assembly (210A) is disposed in the first cavity (240A) defined by the second magnetic gearbox assembly (210B), wherein the air gap (230) is coaxial with the first spool (160A);

[0165] A second magnetic gearbox assembly (210B) is disposed in a second cavity (240B) defined by a first magnetic gearbox assembly (210A), wherein the air gap (230) is coaxial with the first spool (160A); and

[0166] A first magnetic gearbox assembly (210A) is arranged parallel to the second magnetic gearbox assembly (210B), wherein the air gap (230) is perpendicular to the rotation axis (220) of the first spool (160A).

[0167] 21. A processing system, comprising:

[0168] Memory, including computer-executable instructions; and

[0169] A processor is configured to execute computer-executable instructions and cause the processing system to perform the methods described in any of the provisions of 15-20.

[0170] 22. A non-transitory computer-readable medium comprising computer-executable instructions that, when executed by a processor of a processing system, cause the processing system to perform the method described in any one of clauses 15-20.

[0171] 23. A computer program product embodied on a computer-readable storage medium, the computer program product including code for performing the methods described pursuant to any one of clauses 15-20.

[0172] While the foregoing addresses aspects of this disclosure, other and further aspects of this disclosure may be designed without departing from the essential scope of this disclosure, as defined by the appended claims.

Claims

1. A turbofan engine, comprising: The first magnetic gearbox assembly (210A) is connected to the fan (150) of the turbofan engine (100). The second magnetic gearbox assembly (210B) is connected to the reel (160) of the turbofan engine (100); and The speed controller (500) is configured to adjust the speed of the fan (150) based on the rotational speed of the spool (160) by selectively engaging and disengaging the first magnetic gearbox assembly (210A) from the second magnetic gearbox assembly (210B); The first magnetic gearbox assembly (210A) is configured to be connected to and disconnected from the second magnetic gearbox assembly (210B) via a switch (320) in the winding circuit (310); The adjustment of the fan speed (150) is based on the difference between the reference speed of the fan (150) and the measured speed of the fan (150); The reference speed is based on the operating conditions of the fan (150) and the thrust distribution of the turbofan engine (100). The measured speed is based on the measured magnitude of the magnetic field, and The speed controller (500) controls the rotational speed of the fan (150) by increasing or decreasing the duty cycle of the switch (320) based on the difference between the reference speed of the fan (150) and the measured speed of the fan (150). The duty cycle includes the frequency at which the switch is opened or closed.

2. The engine according to claim 1, wherein: The first magnetic gearbox assembly (210A) includes a permanent magnet array (340). The second magnetic gearbox assembly (210B) includes a rotor winding (330) separated from the permanent magnet array (340) by an air gap (230); and The speed controller (500) is configured to selectively connect and disconnect the first magnetic gearbox assembly (210A) from the second magnetic gearbox assembly (210B) via closing and opening a switch (320) in a winding circuit (310) having the rotor winding (330).

3. The engine according to claim 1 or 2, wherein: The second magnetic gearbox assembly (210B) includes a permanent magnet array (340). The first magnetic gearbox assembly (210A) includes a rotor winding (330) separated from the permanent magnet array (340) by an air gap (230); and The speed controller (500) is configured to selectively connect and disconnect the first magnetic gearbox assembly (210A) from the second magnetic gearbox assembly (210B) via closing and opening a switch (320) in a winding circuit (310) having the rotor winding (330).

4. The engine according to claim 1 or 2, wherein, The first magnetic gearbox assembly (210A) is coaxially positioned within a cavity (240) defined by the second magnetic gearbox assembly (210B).

5. The engine according to claim 1 or 2, wherein, The second magnetic gearbox assembly (210B) is coaxially positioned within the cavity (240) defined by the first magnetic gearbox assembly (210A).

6. The engine according to claim 1 or 2, wherein, The first magnetic gearbox assembly (210A) and the second magnetic gearbox assembly (210B) are electromagnetically connected via a coaxial magnetic field.

7. The engine according to claim 1 or 2, wherein, The speed controller (500) is configured to disconnect the first magnetic gearbox assembly (210A) from the second magnetic gearbox assembly (210B) at least by turning off the switch (320) via a switch driver (560), the switch driver being powered by current generated by the rotation of the first magnetic gearbox assembly (210A) relative to the second magnetic gearbox assembly (210B).

8. The engine according to claim 1 or 2, wherein, The speed controller (500) further includes a speed sensor (520), which includes at least one of the following: Hall effect sensor; Inductive sensors; and Optical isolator sensor.

9. The engine according to claim 1 or 2, further comprising: An engine thrust controller (510) is configured to transmit a reference speed to the speed controller (500) via contactless communication.

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