Electric motor for integration into propulsion engine

Abstract

An electric motor includes a stator assembly (302) coupled to an engine stator component of a propulsion engine (100). The stator assembly (302) includes a stator support assembly (308) fixedly attached to the engine stator component and a stator (314) disposed on a support surface of the stator support assembly. The motor also includes a rotor assembly (304) including a rotor support structure (338) connected to a shaft of the propulsion engine (100) and a rotor (346) attached to the rotor support structure (338) such that the rotor (346) is disposed radially inside the stator (314). The rotor (346) exchanges rotational energy with the shaft to operate as an electric motor or generator.

Description

Technical Field

[0001] This manual generally pertains to electric motors used in conjunction with gas turbine engines. Background Technology

[0002] Integrating an electric motor (e.g., a generator) into a propulsion engine to generate electricity from the mechanical energy produced by the propulsion engine can enhance the capabilities of an aircraft by eliminating the need for bulky energy storage devices on the aircraft. For example, the electricity generated by the electric motor can be used to operate auxiliary thrusters (e.g., electric fans, motors, etc.) to supplement the thrust provided via the turbine engine. However, the introduction of such an electric motor can present challenges related to size, weight, accessibility, and aerodynamic performance. Summary of the Invention

[0003] An electric motor includes a stator assembly coupled to an engine stator component of a propulsion engine. The stator assembly includes a stator support assembly fixedly attached to the engine stator component and a stator disposed on a support surface of the stator support assembly. The motor also includes a rotor assembly comprising a rotor support structure connected to a shaft of the propulsion engine and a rotor attached to the rotor support structure, such that the rotor is disposed radially inside the stator. The rotor exchanges rotational energy with the shaft to operate as an electric motor or generator.

[0004] In another embodiment, the motor includes a stator assembly coupled to an engine stator component of a propulsion engine. The stator assembly includes a stator support assembly fixedly attached to the engine stator component and a stator disposed on a support surface of the stator support structure. The motor also includes a rotor assembly comprising a rotor support structure directly connected to a shaft of the propulsion engine and a rotor attached to the rotor support structure. The rotor is disposed radially inside the stator such that the stator assembly circumferentially surrounds the rotor. In this embodiment, the rotor rotates with the shaft to generate an electrical signal. In this embodiment, the motor receives power from an external source to provide rotational energy to the shaft.

[0005] In another embodiment, the motor includes a stator assembly coupled to an engine stator component of a propulsion engine. The stator assembly includes a stator support assembly fixedly attached to the engine stator component. The stator is disposed on a support surface of the stator support structure. The motor also includes a motor shaft coupled to an end of a shaft of the propulsion engine via an intermediate shaft member extending axially between an end of the shaft and the motor shaft. The motor further includes a bearing support frame extending from the propulsion engine, the bearing support frame including an axial portion extending in an axial direction. The motor also includes a motor bearing extending radially from the axial portion of the bearing support frame to rotatably contact the motor shaft. The motor also includes a sealing member axially disposed behind the motor bearing, the sealing member extending from the axial portion of the bearing support frame to the motor shaft. The motor also includes a rotor assembly including a rotor support structure connected to the motor shaft and a rotor attached to the rotor support structure such that the rotor is disposed radially inside the stator. In this embodiment, the rotor rotates together with the shaft of the propulsion engine via the intermediate shaft member to generate an electrical signal. In this embodiment, the motor receives power from an external source to provide rotational energy to the shaft.

[0006] In another embodiment, the motor includes a stator assembly coupled to an engine stator component of a propulsion engine. The stator assembly includes a stator support assembly fixedly attached to the engine stator component and a stator disposed on a support surface of the stator support assembly. The motor also includes a motor shaft coupled to an end of a shaft of the propulsion engine via an intermediate shaft member extending axially between an end of the shaft and the motor shaft. The motor further includes a bearing support frame extending from the propulsion engine, the bearing support frame defining a bearing cavity together with the motor shaft. The motor also includes first and second motor bearings extending radially from the bearing support frame to rotatably contact the motor shaft. The motor also includes a sealing member axially disposed rearward of the motor bearings, the sealing member extending from the bearing support frame to the motor shaft. The motor also includes a rotor support structure connected to the motor shaft and a rotor attached to the rotor support structure. The rotor rotates with the motor shaft to exchange energy with the shaft of the propulsion engine.

[0007] In another embodiment, the propulsion engine includes a core portion that generates exhaust gas traveling in an axial direction and a turbine section coupled to a shaft. The turbine section receives the exhaust gas and generates mechanical energy to rotate the shaft. The propulsion engine also includes a turbine frame attached to the turbine section, and the turbine frame includes a housing coupled to the turbine section and an inner hub supporting the shaft via a bearing assembly, the bearing assembly including an engine bearing supporting the shaft. The propulsion engine also includes an electric motor, the electric motor including: a stator assembly including a stator support assembly attached to the inner hub and a stator attached to the stator support assembly; a motor shaft coupled to an end of a shaft via an intermediate shaft member extending axially between an end of the shaft and the motor shaft; a bearing support frame attached to and extending radially inward therefrom to define a bearing cavity extending between the bearing support frame and the motor shaft; a motor bearing extending radially from the bearing support frame to rotatably contact the motor shaft; and a rotor assembly. The rotor assembly includes a rotor support structure connected to the motor shaft and a rotor attached to the rotor support structure and extending radially inward from the stator. The rotor rotates with the shaft via the intermediate shaft member to exchange energy with the shaft.

[0008] Additional features, advantages, and embodiments of the processes and systems described herein will be set forth in the following detailed description, and in part, based on the teachings disclosed herein, those skilled in the art will readily understand that such features, advantages, and embodiments are conceived and considered within the scope of this disclosure.

[0009] It should be understood that the foregoing general description and the following detailed description depict various embodiments and are intended to provide an overview or framework for understanding the nature and characteristics of the subject matter claimed and described herein. The accompanying drawings are provided to facilitate a further understanding of the various embodiments and are incorporated in and form 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 subject matter claimed and described herein. Attached Figure Description

[0010] The embodiments illustrated in the accompanying drawings are illustrative and exemplary in nature and are not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments will be understood when read in conjunction with the following drawings, in which the same structures are indicated by the same reference numerals and wherein:

[0011] Figure 1 One or more embodiments according to the present document are described. Figure 1 The image depicts a cross-sectional view of the propulsion engine above its central axis AA.

[0012] Figure 2 One or more embodiments according to the present document are described. Figure 1 An enlarged view of the motor of the propulsion engine depicted in the image;

[0013] Figure 3 Schematic depiction of one or more embodiments of the invention that can be incorporated into Figure 1 A cross-sectional view of the electric motor in the propulsion engine depicted in the image;

[0014] Figure 4 Schematic depiction of one or more embodiments of the invention that can be incorporated into Figure 1 A cross-sectional view of the electric motor in the propulsion engine depicted in the figure; and

[0015] Figure 5 An illustration shows an embodiment or combination thereof according to one or more embodiments described herein. Figure 1 The diagram depicts a cross-sectional view of the electric motor in a propulsion engine. Detailed Implementation

[0016] Reference will now be made to electric motors integrated into propulsion engines, such as turbine engines. The electric motors described herein can be positioned at various axial locations within the propulsion engine (e.g., at the rear end of the propulsion engine, between the ends of the propulsion engine shaft) to facilitate rotational energy exchange between the shaft and the motor. For example, the electric motors described herein may include a stator assembly coupled to a stator component of the engine and a rotor assembly connected to the shaft of the propulsion engine, such that the rotor of the rotor assembly rotates together with the shaft to facilitate rotational energy exchange between the rotor assembly and the shaft. The electric motors described herein can operate in generator mode, where rotational energy from the shaft generates an electrical signal in the stator, which is provided by an electrical connector to other components of the propulsion engine or aircraft; and in electric motor mode, where power is provided to the motor from an external source (e.g., an energy storage device disposed on the aircraft), causing the rotor to change the rotational speed of the shaft.

[0017] In embodiments, the rotor assembly can be directly or indirectly attached to the propulsion engine shaft using different attachment structures that have different effects on shaft vibration. For example, in one embodiment, the rotor assembly includes a rotor support structure directly connected to the propulsion engine shaft, such that the rotor assembly is supported by bearing assemblies already integrated into the propulsion engine. In such embodiments, the rotor support assembly can be designed to have a desired effect on the inherent vibration frequency of the propulsion engine shaft. For example, in one embodiment, the rotor support structure is designed to alter the shaft's vibration frequency. In another embodiment, the electrical load of the motor (e.g., connected via switchable coils in the rotor and stator) can be adjusted to controllably suppress the vibration of the propulsion engine shaft, thereby improving its long-term operability.

[0018] In one embodiment, the rotor assembly is indirectly attached to the propulsion engine shaft via a motor shaft, which is rotatably coupled to the propulsion engine shaft, wherein an intermediate shaft member allows axial and radial displacement of the motor shaft. In this embodiment, the motor can be supported by its own generator bearings to protect it from vibrations of the propulsion engine shaft. Another advantage of this separate shaft and bearing embodiment is that the intermediate shaft member allows the motor shaft to be separated from the engine shaft, thereby protecting the engine from the motor in the event of a failure.

[0019] In one embodiment, the motor may be positioned at the rear of the propulsion engine (e.g., near the turbine rear frame). This positioning advantageously facilitates maintenance and repair of the motor when the propulsion engine and the motor are mounted on the aircraft (e.g., on the wing, fuselage, etc.). Additionally, in another embodiment, the motor may be positioned within the tail cone of the propulsion engine and be directly accessible for repair after non-invasive procedures (e.g., opening the core cowling, removing the rear skin, and removing the tail cone) have been performed on the rest of the propulsion engine. This allows for efficient maintenance of the motor without interfering with the operation of other components of the propulsion engine. Furthermore, various components of the motor (e.g., rotor assembly and stator assembly) may be designed to allow for independent removal from the propulsion engine. This non-invasive access to the motor beneficially facilitates maintenance and repair when the propulsion engine is mounted on the aircraft (e.g., on the wing, fuselage, etc.).

[0020] refer to Figure 1 The diagram schematically depicts a propulsion engine 100. Depending on the implementation, the propulsion engine 100 can take various forms. In the embodiment described herein, the propulsion engine 100 is a high-bypass turbofan engine. However, other types of turbofan engines are contemplated and are within the scope of this disclosure. Figure 1As shown, the propulsion engine 100 includes a motor 300 disposed in a rear portion 104 of the propulsion engine 100. The rear portion 104 is axially positioned downstream of the core portion 220 of the propulsion engine 100 (e.g., in a direction parallel to the central axis AA of the propulsion engine 100). In an embodiment, the motor 300 converts the mechanical energy generated by the propulsion engine 100 (e.g., generated from exhaust gas produced in the core portion 220) into electrical energy, which can be used to power the electrical installations of the propulsion engine 100 or components disposed elsewhere on the aircraft (including components containing the propulsion engine 100). As described herein, positioning the motor 300 in the rear portion 104 of the propulsion engine 100 advantageously facilitates maintenance, repair, and replacement of the motor 300 when the propulsion engine 100 is mounted on the aircraft (e.g., on the wing or fuselage of the aircraft). The motor 300 is designed to be integrated into the propulsion engine 100 via a set of connections that can be removed without intrusive disassembly of the entire propulsion engine 100 (e.g., without detaching the propulsion engine 100 from the aircraft).

[0021] In one embodiment, the motor 300 may be attached to the inner hub 226 of the turbine rear frame 222 of the propulsion engine 100. An exemplary embodiment of the structure of the motor 300 is described in more detail herein. Still referring to... Figure 1 It should be understood that the depicted arrangement of the propulsion engine 100 is merely exemplary and not limiting. For example, in an alternative embodiment, the motor 300 may be axially positioned in front of the core portion 220.

[0022] Positioning the motor 300 in the rear portion 104 provides accessibility but introduces additional design considerations for the propulsion engine 100. The exhaust gas generated via the core portion 220 is at relatively high temperatures (e.g., exceeding approximately 700°C or higher in various embodiments), making cooling the motor 300 beneficial. Furthermore, the rear portion 104 of the propulsion engine 100 may not be directly connected to the aircraft in which the propulsion engine 100 is incorporated. Therefore, electrical signals directed to and from the motor 300 are directed through the propulsion engine 100. In embodiments, for example, the propulsion engine 100 includes an electrical system ( Figure 1 (Not depicted in the text), the electrical system includes connecting the motor 300 to the motor control unit ( Figure 1 Multiple wires (not depicted in the text). In one embodiment, the wires are disposed within a cooling conduit that supplies coolant to the rear portion 104 (e.g., from a bypass section disposed radially outward from the core portion 220). In another embodiment, the wires are disposed outside the cooling conduit.

[0023] In one embodiment, the motor control unit converts the electrical signals generated by the motor 300 (between AC and DC signals, or vice versa) to provide to the propulsion engine 100 or additional components incorporated into the aircraft. In another embodiment, as described in more detail herein, the motor control unit may also provide control signals to the motor 300 to change its operating mode (e.g., between generator and electric motor modes) and / or its load, thereby altering the rotational energy exchange between the motor 300 and the additional components of the propulsion engine 100. In another embodiment, the motor control unit may be located within the propulsion engine 100 at a location removed from the motor 300 (e.g., axially forward of the core portion 220), or elsewhere on the aircraft (e.g., in a pylon).

[0024] Still referencing Figure 1 The propulsion engine 100 includes a fan 201, a low-pressure compressor 202, a high-pressure compressor 204, and a combustor 206. The combustor 206 mixes air compressed by the high-pressure compressor 204 with fuel to produce combustion gases. The combustion gases flow downstream through a high-pressure turbine 208 and a low-pressure turbine 210 to produce pressurized exhaust gases. A first shaft 212 connects the high-pressure compressor 204 to the high-pressure turbine 208. A second shaft 216 connects the low-pressure turbine 210 to the fan 201 and the low-pressure compressor 202. In an embodiment, the high-pressure compressor 204, combustor 206, and high-pressure turbine 208 may collectively form a core portion 220. The core portion 220 can produce combustion gases, which are directed to the low-pressure turbine 210 and then power the fan 201 via the second shaft 216. The low-pressure turbine 210 may include multiple rows of blades that rotate in response to combustion gases from the core portion 220, thereby rotating the second shaft 216 to power the fan 201, the low-pressure compressor 202, and the motor 300.

[0025] The turbine rear frame 222 is positioned behind the low-pressure turbine 210 (e.g., offset from the low-pressure turbine 210 in a rearward direction (e.g., axial direction 272) extending parallel to the central axis AA). The turbine rear frame 222 includes a plurality of struts 224 extending between the inner hub 226 and the outer housing 228. The turbine rear frame 222 provides an exhaust flow path for exhaust gas exiting from the low-pressure turbine 210. The inner hub 226 and the outer housing 228 may be circumferentially surrounding a second shaft 216, and the plurality of struts 224 may be distributed around the second shaft 216. In an embodiment, the plurality of struts 224 serve as outlet guide vanes to straighten the exhaust gas flow, which may flow over the tail cone 230 to improve the performance of the propulsion engine 100. It should be understood that the turbine rear frame 222 may include any number of struts 224 in any arrangement consistent with this disclosure.

[0026] Still referencing Figure 1The propulsion engine 100 includes a core shroud 250 and a rear skin 252. The core shroud 250 defines the flow path of air compressed by the fan 201. In one embodiment, the rear skin 252 is bolted (not depicted) to the housing of the turbine rear frame 222. In another embodiment, exhaust gas exits the propulsion engine 100 via an outlet 254 defined by the turbine rear frame 222, the rear skin 252, and the tail cone 230.

[0027] Now for reference Figure 2 It shows that in Figure 1 A detailed view of a cross-sectional portion of the motor 300, depicted within the dashed line boundary. In the depicted embodiment, the motor 300 includes a stator assembly 302 and a rotor assembly 304. The stator assembly 302 is directly connected to the propulsion engine 100 via a first engine stator component 260 and a second engine stator component 270. The first engine stator component 260 and the second engine stator component 270 may vary depending on the specific location of the motor 300 within the propulsion engine 100. For example, as described herein... Figure 1 As described, the motor 300 is disposed in the rear portion 104 of the propulsion engine 100. In such an embodiment, the first engine stator component 260 may be a flow-limiting structure, such as... Figure 1 The turbine rear frame 222 depicted (e.g., stator assembly 302 may be attached to inner hub 226) and the second engine stator component 270 may be another component (e.g., turbine component, such as bearing support structure, etc.) extending radially between the second shaft 216 and inner hub 226. Alternative locations for the motor 300 are contemplated and are within the scope of this disclosure. For example, in an embodiment, the motor 300 is disposed between the end of the second shaft 216 (e.g., axially forward of the rear end 217 of the second shaft 216 and the turbine rear frame 222). In such an embodiment, the first engine stator component 260 may be another flow path defining structure (e.g., intermediate turbine frame, etc.). Various connection points between the motor 300 and the propulsion engine 100 are contemplated and are within the scope of this disclosure.

[0028] Stator assembly 302 includes a stator 314 and rotor assembly 304 includes a rotor 346. In the depicted embodiment, rotor assembly 304 is disposed radially inside stator assembly 302 (e.g., the entire rotor assembly 304 is disposed closer to the second shaft 216 than stator assembly 302). In an embodiment, stator assembly 302 circumferentially surrounds rotor assembly 304 such that rotor assembly 304 is radially disposed between stator assembly 302 and the second shaft 216 of propulsion engine 100. In an embodiment, motor 300 operates as a generator to convert rotational energy of second shaft 216 (e.g., during flight operation of propulsion engine 100) into electrical energy that can be transmitted to other components of the aircraft. In an embodiment, motor 300 operates as a motor to provide torque to second shaft 216 (e.g., to improve the operating efficiency of propulsion engine 100).

[0029] The inner rotor configuration of the motor 300 is advantageous for its compactness (e.g., aerodynamic performance) and operability. For example, during operation of the motor 300, the inner rotor configuration can promote its long-term operability in embodiments where the stator assembly 302 is located radially inward of the rotor assembly 304 by reducing the rotational load applied to the structural components supporting the rotor 346. Furthermore, Figure 2 The inner rotor configuration of the motor 300 depicted in the diagram helps the stator assembly 302 act as a shield to prevent damaged rotor components from traveling radially outward and affecting additional components of the propulsion engine 100. For example, if the motor 300 fails, a portion of the rotor assembly 304 may break off and disconnect from the second shaft 216. If left unobstructed, such a damaged component could interfere with the operation of the propulsion engine 100. However, due to the inner rotor configuration of the motor 300, such a damaged rotor component is contained within the rotor cavity 370 defined by the stator assembly 302. The containment of debris by the stator assembly 302 reduces the likelihood that a motor failure will affect the operation of other components of the propulsion engine 100 or high-energy components released from the propulsion engine 100. Embodiments with an outer rotor configuration are contemplated and are within the scope of this disclosure, but may include a debris shield disposed radially outward of the rotor assembly 304.

[0030] exist Figure 2In the illustrated embodiment, the motor 300 is directly connected to the second shaft 216 via a rotor support structure 338 of the rotor assembly 304. In this embodiment, the rotor support structure 338 includes attachment elements (e.g., grooves, protrusions, etc., not shown) that slidably engage with corresponding attachment elements on the second shaft 216. For example, in this embodiment, the rotor support structure 338 may slidably engage with the second shaft 216 at its rear end 217. A locking nut (not depicted) secures the rotor support structure 338 to the second shaft 216, allowing the rotor assembly 304 to rotate together with the second shaft 216 to facilitate the generation of electricity via the rotation of the second shaft 216.

[0031] This embodiment, in which the rotor assembly 304 is directly attached to the second shaft 216, may be referred to herein as an "embedded generator embodiment." In the embedded generator embodiment, the rotor assembly 304 may be at least partially supported by a bearing assembly supporting the second shaft 216 (e.g., an engine bearing assembly—not depicted—supporting the rear portion 104 of the propulsion engine 100, axially positioned near the turbine rear frame 222). The embedded generator embodiment may be advantageous because the motor 300 can be used as a shaft natural frequency damper. In this embodiment, components of the rotor assembly 304 (e.g., the rotor support structure 338) may be structurally designed to modify the natural frequency of the second shaft 216 (e.g., altering the natural vibration frequency of the second shaft 216 compared to an embodiment without the motor 300). For example, in this embodiment, the stiffness and volume of the rotor support structure 338 may be selected to remove the natural vibration frequency of the second shaft 216 from the range of vibration modes that the vibration of the second shaft 216 might excite in other components of the propulsion engine 100, thereby avoiding structural integrity problems associated with high-amplitude oscillations.

[0032] In one embodiment, the motor 300 may be designed to variably influence the natural vibration frequency of the second shaft 216 via external control. In the depicted embodiment, for example, the motor 300 may be communicatively coupled (e.g., via wires 336 and 342 and electrical connection 328 described herein) to a motor control unit 380. The motor control unit 380 may control the motor 300 by changing the electrical load based on power demand. In one embodiment, the motor control unit 380 is located at a different axial position from the motor 300 within the propulsion engine 100. In another embodiment, the motor control unit 380 is located at the same axial position as the motor 100 within the propulsion engine.

[0033] In one embodiment, for example, the motor control unit 380 receives instructions from another component associated with the aircraft (e.g., an engine power control unit) to adjust the motor load to change the rotational energy extracted from the second shaft 216 via the rotation of the rotor 346, thereby controllably suppressing vibration of the second shaft 216. For example, the motor control unit 380 may change the electrical load of the motor 300 in response to detected vibration of the second shaft 216 (e.g., by disconnecting and connecting electrical connections between its coils) to suppress the detected vibration. This electrical load control of the motor control unit 380 can occur in both generator operating mode and motor operating mode of the motor 300.

[0034] Still referencing Figure 2 The rotor assembly 304 also includes a rotor attachment arm 340 extending axially forward from the end of the rotor support structure 338. The rotor attachment arm 340 holds the rotor 346 in a relationship spaced apart from the stator 314 and the second shaft 216. In an embodiment, the rotor 346 includes a plurality of permanent magnets circumferentially distributed around the stator 314, such that rotation of the rotor 346 about the stator 314 generates an AC electrical signal. It should be understood that alternative configurations of the rotor 346 are contemplated depending on the implementation of the motor 300. For example, in an embodiment, the rotor 346 may include a plurality of electromagnets and active circuitry. Various implementations are contemplated in which the motor 300 is configured as an induction generator, a switched reluctance generator, an asynchronous AC motor, or any suitable type of generator.

[0035] In one embodiment, the stator assembly 302 circumferentially surrounds the rotor assembly 304. In another embodiment, the stator assembly 302 (e.g., the stator support assembly 308 described herein) includes multiple circumferential segments, each of which can be individually detached from the propulsion engine 100 to facilitate its removal. This embodiment, incorporating multiple circumferential segments, may be particularly advantageous in embodiments where the motor is centrally located within the propulsion engine 100 (e.g., at an end remote from the second shaft 216), as accessing the motor 300 for maintenance or replacement may be more time-consuming in such embodiments.

[0036] In the depicted embodiment, stator assembly 302 is attached to a first engine stator component 260 and a second engine stator component 270 via a first connecting bolt 327 and a second connecting bolt 329, respectively. Stator assembly 302 includes a stator support assembly 308 that holds stator 314 in a desired position relative to rotor 346. Stator support assembly 308 includes a stator support arm 312. Stator support arm 312 extends in an axial direction 272 (e.g., parallel to a second shaft 216) and defines a stator support surface 313, wherein stator 314 is attached to stator support assembly 308.

[0037] In one embodiment, the stator support arm 312 extends axially over the entire rotor 346 in the axial direction 272 to define a rotor cavity 370 extending between the stator support arm 312 and the second shaft 216. In another embodiment, the length of the stator support arm 312 in the axial direction 272 is greater than the length of the rotor 346. In addition to providing structural support for the stator 314, the stator support arm 312 also helps to accommodate any fragments associated with the rotor assembly 304 (e.g., in conjunction with a fragment shield disposed radially outside the stator support arm 302), thereby preventing the release of high-energy components outside the propulsion engine 100. That is, the stator support arm 312 can serve as a shield to prevent a failure of the rotor assembly 304 from interfering with the operation of other components of the propulsion engine 100, or to prevent the rotor assembly 304 from launching high-energy fragments outside the propulsion engine 100. In this embodiment, the stator support arm 312 is the sole receiving mechanism of the propulsion engine 100 for accommodating such fragments from the rotor assembly 304. That is, the inner rotor structure of the motor 300 can eliminate the need for the fragment shielding component surrounding the motor 300.

[0038] In one embodiment, the stator support arm 312 includes a substantially cylindrical structure surrounding a second axis 216. In another embodiment, the substantially cylindrical structure is a monolithic continuum. In yet another embodiment, the stator support arm 312 includes a plurality of circumferential segments, each of which is connected to each other to facilitate individual removal of each circumferential segment radially away from the second axis 216. In yet another embodiment, the plurality of circumferential segments are discontinuous in the circumferential direction. That is, in such an embodiment, the stator support arm 312 may include gaps around its circumference.

[0039] In this embodiment, the structure of the stator support assembly 308 facilitates both electrical and fluid connections of the motor 300. For example, in Figure 2 In the illustrated embodiment, the motor 300 includes a connector support 316 extending radially between the first engine stator component 260 and the stator support arm 312. In this embodiment, the connector support 316 includes at least one opening 318 for supporting the electrical connection device 328. It should be understood that embodiments are also contemplated in which the motor 300 does not include the connector support 316, or the connector support 316 is disposed with... Figure 2The locations shown are different. The electrical connection device 328 can conductively connect the wire 336 from the stator 314 to the external wire 342. In an embodiment, the connector support 316 serves as a retainer for the electrical connection device 328 to facilitate electrical connection of the motor 300 to other components of the propulsion engine 100. In an embodiment, the connector support 316 includes a plurality of openings 318 circumferentially distributed around the stator support assembly 308. The electrical connector can extend through each of the plurality of openings to facilitate the provision of electrical signals generated by the motor 300 to external components. It should be understood that alternative locations are contemplated for the electrical connection device 328. That is, the electrical connection device 328 can be positioned along the wires 336 and 342 in relation to… Figure 2 Alternative locations depicted in the diagram may differ (e.g., axially forward of motor 300). In such embodiments with alternative positioning of the electrical connection device 328, motor 300 may not include connector support 316.

[0040] In one embodiment, the motor 300 includes a cooling system 350 that distributes coolant to various portions of the motor 300. In the depicted embodiment, the cooling system 350 includes an inlet manifold 352 and a stator manifold 354. The inlet manifold 352 receives coolant air from a portion of the propulsion engine 100 outside the motor 300. In one embodiment, the inlet manifold 352 is part of or connected to another cooling conduit of the propulsion engine 100. In one embodiment, the inlet manifold 352 may be directed through a first engine stator component 260 (e.g., via...). Figure 1 (One of the struts 224 of the turbine rear frame 222 depicted). The stator manifold 354 supplies coolant to the stator 314 to maintain its temperature within a suitable operating range. In embodiments, one or more of the wires and electrical connections are disposed within the cooling system 350. For example, in the depicted embodiment, wires 336 and 342 extend through the stator manifold 354 and the inlet manifold 356, respectively, and are conductively connected within the stator manifold 354 via electrical connections 328. Embodiments in which the wires are disposed outside the cooling system 350 are also contemplated. In embodiments, the stator support arm 312 includes holes or openings to access different... Figure 2 The cooling manifolds depicted in the text.

[0041] exist Figure 2In the illustrated embodiment, the electrical and fluid connections via the cooling system 350 are located at the rear end of the stator 314 (e.g., via the connection portion 358 of the stator manifold 354). It should be understood that alternative embodiments are contemplated and are within the scope of this disclosure. For example, in an embodiment, the wire 336 may extend from the axial front end of the stator 314, and the stator manifold 354 may extend through the stator support arm 312 to facilitate attachment and connection to the axial front end of the stator (e.g., the stator manifold 354 may not include the connection portion 358 including the bend, as in the depicted embodiment). In such an embodiment, the electrical connection device 328 may also be located axially forward of the stator 314. For example, the electrical connection device 328 may be supported within or outside a portion of the stator manifold 354 extending through the stator support arm 312 to facilitate electrical connection to an external wire 342. Such embodiments may not include the connector support 316 (the depicted embodiment may also exclude the connector support 316). Various combinations of electrical and fluid connection structures are contemplated and are within the scope of this disclosure.

[0042] In one embodiment, the motor 300 includes a heat shield 348. In another embodiment, the heat shield 348 is not directly attached to the second shaft 216, but rather circumferentially surrounds the rear end 217 of the second shaft 216, the stator assembly 302, and the rotor assembly 304. In another embodiment, the heat shield 348 is attached to a first engine stator component 260. For example, in one embodiment, the heat shield 348 is attached to a connecting flange 310 of the first engine stator component 260 via a first connecting bolt 327. In another embodiment, the heat shield 348 includes at least two components. In another embodiment, for example, the heat shield 348 includes a stator portion circumferentially surrounding the stator assembly 302 and a rotor portion extending axially rearward of the rotor 346. In another embodiment, individual portions of the heat shield 348 can be individually removed from the propulsion engine 100 to facilitate access to the rotor assembly 304 without disrupting the connection of the stator assembly 302.

[0043] Figure 2 The view depicted corresponds to a single circumferential section of the motor 300. Therefore, it should be understood that the motor 300 may include any number of circumferentially distributed sections around the second axis 216. Figure 2 The components depicted in the text. Figure 2 The components depicted can also be separated axially. That is, Figure 2 Each component depicted is a continuous segment (e.g., stator support arm 312) that can be divided into multiple segments extending in the axial direction 272 and extending to each other. In an embodiment, the motor 300 includes similar components distributed around its circumference. Figure 2The cooling system 350 depicted includes multiple cooling systems (e.g., having multiple manifolds, electrical connectors, and wires extending therethrough). Furthermore, components of the motor 300 (e.g., stator support assembly 308, heat shield 348, etc.) can be connected to the propulsion engine 100 at any number of points along the circumference of the motor 100. That is, the motor 300 may include a plurality of first connecting bolts 327 and second connecting bolts 329 distributed around its circumference.

[0044] The various components of the electric motor 300 and the propulsion engine 100 have been described, and now it is possible to understand about Figure 2 and Figure 3 The various advantages of the described structure. For example, refer to Figure 1 To make the motor 300 fully accessible, the tail cone 230 can be removed. After removing the tail cone 230, at least a portion of the motor 300 can be removed from the propulsion engine 100. Depending on the type of operation being performed and the process being followed, all or part of the motor 300 can be removed. For example, in an embodiment, a plurality of first connecting bolts 327 and second connecting bolts 329 attaching the stator assembly 302 to the first engine stator component 260 and the second engine stator component 270 can be removed to facilitate the removal of the heat shield 348. The connection between the rotor support structure 338 and the second shaft 216 can then be loosened, thereby facilitating the removal of the rotor assembly 304 for replacement and / or maintenance. The stator assembly 302 can also be removed from the first engine stator component 260 and the second engine stator component 270.

[0045] In this embodiment, instead of removing the stator assembly 302, the rotor assembly 304 can be removed from the second shaft 216 without removing the connections at the plurality of first connecting bolts 327 and second connecting bolts 329. The non-radial overlap structure of the stator assembly 302 and the rotor assembly 304 facilitates access to and removal of the rotor assembly 304 from the propulsion engine 100 without damaging the stator assembly 302, and facilitates rapid and efficient maintenance operations.

[0046] The manner in which the electric motor 300 is positioned and connected within the propulsion engine 100 thus facilitates the access and removal of the electric motor 300 without removing the propulsion engine 100 from its position in front of the turbine rear frame 222 (e.g., Figure 2Any component located in the opposite direction of the axial direction 272 depicted in the diagram, or radially inward. When the propulsion engine 100 is mounted on the wing or fuselage of an aircraft, this non-invasive approach to the motor 300 facilitates the maintenance or replacement of various components of the motor 300, minimizing the time during which the aircraft may be inoperable if the motor 300 requires maintenance. Furthermore, the manner in which the motor 300 is connected to the various components of the propulsion engine 100 provides a streamlined process for removing the motor 300 from the propulsion engine 100.

[0047] Now for reference Figure 3 It schematically depicts what can be integrated into a propulsion engine (e.g., as shown in this article regarding...). Figure 1 A cross-sectional view of the motor 400 in the described propulsion engine 100. The motor 400 may include, as described herein, the electric motor 400. Figure 2 The components of the described motor 300. Therefore, in Figure 3 The same reference numerals are used to indicate the combination of such identical components. Motor 400 is also an embodiment of an embedded generator, including a rotor 346 fixedly attached to a second shaft 216. Motor 400 includes... Figure 2 The motor 300 depicted in the diagram describes a stator assembly 302. The motor 400 also includes a rotor assembly 402, which is structurally similar to... Figure 3 The rotor assembly 304 differs in that the rotor assembly 402 includes a rotor support structure 404 that extends axially forward from the point where it is attached to the second shaft 216. In an embodiment, the rotor support structure 404 is connected to the second shaft 216 at its rear end 217 (e.g., by engaging a feature on the second shaft 216). Figure 3 As shown, the rotor support structure 404 extends in an axially forward direction, and the rotor attachment arm 340 extends axially rearward from the end of the rotor support structure 404. This axially forward extension of the rotor support structure 404 provides additional space behind the motor 400 for handling additional components (e.g., coolant manifolds, fuel lines, etc.) that can be incorporated into the motor 400 and propulsion engine 100. In this embodiment, the rotor support structure 404 extends only in the radial direction 274.

[0048] Now for reference Figure 4 It schematically depicts what can be integrated into a propulsion engine (e.g., the one discussed in this paper). Figure 1 A cross-sectional view of the motor 500 in the described propulsion engine 100. The motor 500 may include, as described herein, [missing information]. Figure 2 The components of the described motor 300. Therefore, in Figure 4The same reference numerals are used to indicate the assembly of such identical components. The motor 500 differs from the motor 300 in that the motor 500 is not directly connected to the second shaft 216, but is indirectly connected to the second shaft 216 via a motor shaft 502. The motor shaft 502 is attached to the rear end 217 of the second shaft 216 via an intermediate shaft member 504. In an embodiment, the intermediate shaft member 504 is attached to the second shaft 216 such that axial and radial vibrations of the second shaft 216 are not transmitted to the motor shaft 502. For example, in an embodiment, the intermediate shaft member 504 includes a sleeve shaft having a first spline (not shown) at its front end 505. The first spline can be inserted into an opening at the rear end 217 of the second shaft 216 to rotatably connect the second shaft 216 and the motor shaft 502. A second spline (not depicted) at the rear end 507 of the intermediate shaft member 504 can be inserted into a connecting end 503 of the motor shaft 502. This splined connection between motor shaft 502 and second shaft 216 allows for axial and radial movement of motor shaft 502 relative to second shaft 216 without altering the natural vibration frequency of second shaft 216. In an embodiment, intermediate shaft member 504 may include a bellows spring member instead of a sleeve shaft to allow relative axial and radial movement of motor shaft 502 relative to second shaft 216. In an embodiment, intermediate shaft member 504 includes a shear section configured to separate (e.g., break) when subjected to a predetermined shear load. In an embodiment, intermediate shaft member 504 and motor shaft 502 may be integrated into a single component.

[0049] The motor shaft 502 is radially supported via a generator bearing assembly 516, which is attached to the second engine stator component 270 via bolted connection 552. The generator bearing assembly 516 includes a bearing support frame 514 extending radially between the motor shaft 502 and the second engine stator component 270. As depicted, the bearing support frame 514 includes an axial portion 518 that, together with the motor shaft 502, defines a bearing cavity 520. A first bearing support arm 519 and a second bearing support arm 521 extend from the bearing support frame 514 in the axial direction 272. A first generator bearing 522 extends between the first bearing support arm 519 and a first portion of the motor shaft 502, and a second generator bearing 524 extends between the second bearing support arm 521 and a second portion of the motor shaft 502 to rotatably contact the motor shaft 502 (e.g., an inner ring connected to the motor shaft 502 can accommodate the first generator bearing 522 and the second generator bearing 524 to provide this rotatable contact). Depending on the implementation, the first generator bearing 522 and the second generator bearing 524 may include various types of bearings (e.g., ball bearings, roller bearings, etc.). The first generator bearing 522 and the second generator bearing 524 protect the motor 500 from radial and axial movement of the second shaft 216.

[0050] Figure 4 An engine bearing assembly 538 associated with the propulsion engine 100 is also depicted. For example, in one embodiment, the engine bearing assembly 538 may support a second shaft 216 via a second engine stator component 270 (e.g., the second engine stator component 270 may include a support structure extending radially inward from the inner hub 226 of the turbine rear frame 222). The engine bearing assembly 538 includes an engine bearing support arm 540 extending from the second engine stator component 270. The engine bearing support arm 540, together with the second shaft 216, defines an engine bearing cavity 541. An engine bearing 542 is disposed within the engine bearing cavity 541 and extends between the engine bearing support arm 540 and the second shaft 216. The engine bearing 542 rotatably contacts the second shaft 216 such that the second engine stator component 270 supports the second shaft 216.

[0051] Therefore, the motor 500 is supported by dedicated bearings (e.g., first generator bearing 522 and second generator bearing 524) on the motor shaft 502 to protect the motor 500 from vibrations of the second shaft 216. In an embodiment, the engine bearing cavity 541 and bearing cavity 520 are fluidly isolated from each other to mitigate the risk of contamination of the engine bearing assembly 538 during maintenance of the motor 500. For example, in Figure 4 In the illustrated embodiment, the generator bearing assembly 516 includes a first sealing member 526 extending between a first bearing support arm 519 and a motor shaft 502, and a second sealing member 528 extending between a second bearing support arm 521 and a motor shaft 502. The first sealing member 526 and the second sealing member 528 may be constructed of a suitable compliant material (e.g., a labyrinth air seal) to create a seal at the interface between the first sealing member 526 and the second sealing member 528 and the motor shaft 502.

[0052] The engine bearing assembly 538 also includes a sealing member 544 disposed between the engine bearing support arm 540 and the second shaft 216. The sealing member 544 creates a seal at its interface with the second shaft 216. The sealing member 544 is axially disposed between the engine bearing 542 and the generator bearing assembly 516, thereby fluidly isolating the engine bearing assembly 538 from the generator bearing assembly 516. This isolation of the bearing assemblies facilitates the supply of lubricant from a separate source, reducing the risk of contamination during maintenance. For example, in the depicted embodiment, the propulsion engine 100 includes an engine bearing lubrication system 546 and a generator bearing lubrication system 530. The generator bearing lubrication system 530 includes an oil supply line 531 supported by a bearing support frame 514. In an embodiment, the oil supply line 531 extends into the bearing cavity 520 through an opening in an axial portion 518. The generator bearing lubrication system 530 also includes an oil injector 532, which has an outlet located near the first generator bearing 522 and the second generator bearing 524, such that during operation of the first generator bearing 522 and the second generator bearing 524, oil from a lubricant source (not shown) passes through an oil supply line 531 and is sprayed onto the surfaces of the first generator bearing 522 and the second generator bearing 524 to provide lubrication and cooling. The generator bearing lubrication system 530 also includes an oil removal device 534 that facilitates oil circulation out of the bearing cavity 520.

[0053] The engine bearing lubrication system 546 includes an oil supply line 548 and an injector 550, the injector 550 including an outlet located near the engine bearing 542 to provide lubrication during operation of the engine bearing 542. Lubricant is also supplied to the generator bearing assembly 516 and the engine bearing assembly 538 using separate bearing lubrication systems (e.g., separate oil supply lines 531 and 548). Figure 4 The embodiments depicted mitigate the risks associated with maintaining the motor 500.

[0054] While the depicted embodiments combine an oil-based generator bearing lubrication system 530 and an engine bearing lubrication system 546, it should be understood that alternative lubrication systems using different types of lubricants are contemplated and are within the scope of this disclosure. Various types of fluid-based lubricants (e.g., synthetic polymer-based lubricants), gas-based lubricants, or solid lubricants may also be used according to this disclosure. Isolating separate lubrication systems associated with the generator and engine bearings generally avoids complications in the engine bearing assembly due to maintenance of the motor 500, thereby preventing interference with the operation of the rest of the propulsion engine 100.

[0055] Still referencing Figure 4 Motor 500 and the motor mentioned in this article Figure 2The motor 300 described also differs in that it includes a rotor assembly 506, which is structurally different from the rotor assembly 304 described herein. The rotor assembly 506 includes a rotor support structure 508 attached to the motor shaft 502 via a mounting flange 510. The rotor support structure 508 is attached to the mounting flange 510 by connecting bolts 512 extending through the mounting flange 510 and the rotor support structure 508. The rotor support structure 508 extends from the motor shaft 502, and a rotor attachment arm 340 extends axially therefrom to support the rotor 346 in a desired position. In an embodiment, the rotor support structure 508 extends diagonally from the motor shaft 502 (e.g., similar to the description herein). Figure 2 and Figure 3 The rotor support structures described are 338 and 404.

[0056] In the depicted embodiment, the rotor 346 is positioned radially inside the stator assembly 302. As discussed herein, this inner rotor design facilitates the independent removal of the rotor assembly 506. Because the mounting flange 510 of the motor shaft 502 is positioned axially rearward of the bearing support frame 514, the connecting bolts 512 can be accessed without removing the bearing support frame 514, allowing the rotor assembly 506 to be removed independently of the stator assembly 302. Furthermore, due to the inner rotor configuration of the motor 500, the stator support arm 312 can serve as a fragment shield for accommodating any damaged parts of the rotor assembly 506. It should be understood that embodiments incorporating various aspects of the motor 500 (e.g., the motor shaft 502, the intermediate shaft member 504, the generator bearing assembly 516) are also contemplated, wherein the rotor 346 is positioned radially outside the stator assembly 302.

[0057] The separate shaft connection of the motor 500 via the motor shaft 502 further facilitates the separation of the motor 500 from the propulsion engine 100 by separating the intermediate shaft assembly 504. For example... Figure 4 As shown, the propulsion engine 100 includes a separation device 536 extending from the second engine stator component 270. The separation device 536 overlaps axially with the intermediate shaft component 504 such that when the separation device 536 is activated, it performs an action on the intermediate shaft component 504 to separate the motor shaft 502 from the second shaft 216, thereby protecting the second shaft 216 from the effects of a motor 500 failure through the mechanical disconnection of the motor 500 from the second shaft 216.

[0058] To facilitate the removal of the motor 500 from the propulsion engine 100 via the splines of the intermediate shaft member 504, and in accordance with the provisions of this article... Figure 3 Compared to the described generator assembly 300, the way the stator assembly 302 is connected to the propulsion engine 100 can be modified. For example... Figure 4As shown, the stator assembly 302 is not directly connected to the second engine stator component 270, but rather to the bearing support frame 514. The bearing support frame 514 is connected to the second engine stator component 270 via a first connecting bolt 552, and the stator support arm 312 is connected to the bearing support frame 514 via a second connecting bolt 554. An axial portion 556 of the bearing support frame 514 extends between the first connecting bolt 552 and the second connecting bolt 554 to axially separate the stator support arm 312 from the second engine stator component 270. In an embodiment, the first connecting bolt 552 can be removed to facilitate the removal of the motor shaft 502 from the intermediate shaft component 502 via a spline connection. Therefore, the spline connection provided by the intermediate shaft component 504 facilitates the removal of the entire motor 504 (e.g., motor shaft 502, bearing support frame 514, generator bearing assembly 516, rotor assembly 506, and stator assembly 302) as a single module, reducing the risk of contamination. The intermediate shaft component 502 can also be removed after the motor 500 has been removed.

[0059] In one embodiment, the second connecting bolt 554 can be loosened to facilitate the removal of the stator assembly 302 without using the separation device 536 (e.g., removing connecting bolts 327, 554, and 512 can facilitate the removal of the rotor assembly 506 and stator assembly 302 from the propulsion engine 100 independently of the bearing support frame 514). Therefore, the depicted design promotes flexibility in operations that can be performed to remove the motor 500 (or a portion thereof) from the propulsion engine 100. In one embodiment, the bearing support frame 514 and the stator support arm 312 can be constructed from different materials to achieve the desired functionality and durability. In another embodiment, the stator support arm 312 and the bearing support frame 514 are integrated as a single component.

[0060] Now for reference Figure 5 It schematically depicts what can be integrated into a propulsion engine (e.g., the one discussed in this paper). Figure 1 A cross-sectional view of the motor 600 in the described propulsion engine 100. The motor 600 may include, as described herein, the... Figure 5 The components of the described motor 500. Therefore, in Figure 5 The same reference numerals are used to indicate the assembly of such identical parts. Motor 600 is the same as described herein. Figure 4 The difference between the described motor 500 and the motor 600 is that the motor 600 includes a generator bearing assembly 602 and an engine bearing assembly 604, which are disposed in a common reservoir 640 defined at least partially by a bearing support frame 514 and a second engine stator component 270. Figure 5 As shown, the generator bearing assembly 602 includes, regarding Figure 4The first generator bearing 522 and the second generator bearing 524 are described, but only a single generator bearing seal member 622 is included, axially disposed behind the second generator bearing 524. The engine bearing assembly 604 includes, regarding... Figure 4 The engine bearing 542 is described, but includes a single engine bearing seal member 606 axially disposed in front of the engine bearing 542. Seals 622 and 606 seal a common reservoir 640 to contain lubricant supplied to the bearing.

[0061] In the motor 600, the common reservoir 640 is not axially sealed between the first generator bearing 522 and the second generator bearing 524 and the engine bearing 542. That is, regarding Figure 4 The described bearing cavities 520 and 541 are not fluidly isolated from each other. This lack of a seal between the bearings allows for the use of a common lubrication source to lubricate the first generator bearing 522, the second generator bearing 524, and the engine bearing 542. For example, in the depicted embodiment, a bearing lubrication system 608 is used to supply lubricant to the engine bearing 542 and the first and second generator bearings 522 and 524. The bearing lubrication system 608 includes an oil supply line 610 extending from a lubricant source (not shown) into a coolant cavity 562. The oil supply line 610 branches into a generator section 614 extending axially rearward into the bearing cavity 520 and an engine section 612 extending axially forward into the bearing cavity 541. An oil nozzle 618 at the end of the generator section 614 includes an outlet for supplying oil to the first generator bearing 522 and the second generator bearing 524. An oil nozzle 620 at the end of the engine section 612 includes an outlet for supplying oil to the engine bearing 542. The bearing lubrication system 608 also includes one or more discharge channels 626 disposed near each of bearings 522, 524, and 542 for receiving oil after it has been applied to bearings 522, 524, and 542. Embodiments may incorporate the discharge channels in a portion of the second engine stator assembly 270 disposed near the separator 536. Discharge channels 626, 628, and 630 may discharge oil near bearings 522, 524, and 542 into a common reservoir 640. A cleaning device 624 may direct the oil to a cleaning line for filtration and reuse.

[0062] Therefore, the common reservoir 640 of the motor 600 is advantageous for using a single bearing lubrication system 608 (e.g., including a single oil supply line 610 from a lubrication source), and includes more than about Figure 4 The described motor 500 has a simpler structure than the multiple lubrication systems associated with it (e.g., generator bearing lubrication system 530 and engine bearing lubrication system 546). (Regarding...) Figure 4Compared to the described motor 500, the reduction of oil lines, seals, and connections in motor 600 can reduce the weight and complexity of motor 600.

[0063] Based on the foregoing description, it should be understood that the motor can be integrated into the propulsion engine of an aircraft. The stator assembly of the motor can be coupled to one or more engine stator components of the propulsion engine, while the rotor assembly can be directly or indirectly coupled to the shaft of the propulsion engine to facilitate rotational energy exchange between the shaft and the motor. The rotor assembly can be directly connected to the shaft via a rotor support structure attached to the shaft, or indirectly connected to the shaft via an intermediate shaft member and the motor shaft. In such an embodiment, the motor can be supported on its own bearings to protect the motor from shaft vibration and the shaft from motor vibration. The motor can also be removed entirely via a splined connection to the intermediate shaft member to avoid the risk of magnetic contamination of the motor during maintenance. When the propulsion engine is mounted on the aircraft, the motor can be constructed and positioned to facilitate relatively easy access and removal for maintenance purposes.

[0064] As used herein, the term “about” means that a quantity, size, formulation, parameter, and other quantity and characteristic is not and need not be precise, but may be approximate and / or larger or smaller as required, reflecting tolerances, conversion factors, rounding, measurement errors, and other factors known to those skilled in the art. When the term “about” (or “substantially” or “approximately”) is used to describe the endpoints of a value or range, the specific value or endpoint referred to is included. Regardless of whether the endpoints of a numerical value or range in the specification are described as “about,” two embodiments are described: one modified by “about” and one not modified by “about.” It will be further understood that each endpoint of a range is significant relative to and independent of the other endpoint. For example, approximate language may refer to a margin of 1%, 2%, 4%, 10%, 15%, or 20% of the endpoints of a single value, a range of values, and / or a range of defined values.

[0065] The directional terms used in this article (e.g., up, down, right, left, front, back, top, bottom) are used only with reference to the drawn diagrams and are not intended to imply absolute orientation.

[0066] Unless otherwise expressly stated, no method described herein is intended to be construed as requiring its steps to be performed in a particular order, nor is it intended to require any particular device orientation. Therefore, in any respect, if a method claim does not actually describe the order in which its steps are followed, or if any device claim does not actually describe the order or orientation of individual components, or if the claims or specification do not otherwise specifically state that the steps are limited to a particular order, or do not describe a particular order or orientation of the device components, then no order or orientation is intended to be inferred. This applies to any possible non-explicit basis of interpretation, including: logical questions relating to the arrangement of steps, the flow of operations, the order of components, or the orientation of components; the simple meaning derived from grammatical organization or punctuation; and the number or type of embodiments described in the specification.

[0067] As used herein, unless the context clearly specifies otherwise, the singular forms “a,” “an,” and “the” include plural references. Thus, for example, a reference to a component “a” includes aspects having two or more such components, unless the context clearly specifies otherwise.

[0068] Further aspects of the invention are provided by the subject matter in the following clauses:

[0069] 1. An electric motor comprising: a stator assembly coupled to an engine stator component of a propulsion engine, the stator assembly including: a stator support assembly fixedly attached to the engine stator component; a stator disposed on a support surface of the stator support assembly; and a rotor assembly including a rotor support structure connected to a shaft of the propulsion engine and a rotor attached to the rotor support structure such that the rotor is disposed radially inside the stator, wherein the rotor exchanges rotational energy with the shaft to operate as an electric motor or generator.

[0070] 2. The motor according to any of the preceding clauses, wherein the stator assembly circumferentially surrounds the rotor assembly such that the rotor assembly is radially disposed between the shaft and the stator assembly.

[0071] 3. The motor according to any of the preceding clauses, wherein the stator support assembly includes a stator support arm extending parallel to the shaft in an axial direction, the stator support arm defining the support surface, wherein the stator support arm is at least as long as the rotor assembly in the axial direction, such that the entire rotor assembly is disposed in a rotor cavity defined by the stator support arm, and the stator support arm isolates the propulsion engine from the rotor assembly.

[0072] 4. The motor according to any of the preceding clauses, further comprising: an electrical connection device coupled to the stator support assembly; and a wire extending from the stator to the electrical connection device.

[0073] 5. The motor according to any of the preceding clauses, further comprising a motor control unit electrically connected to the stator, wherein the motor control unit is configured to switch the operation of the motor between a generator mode in which electricity is generated by rotation of the shaft and a motor mode in which the stator adds rotational energy to the shaft.

[0074] 6. The motor according to any of the preceding clauses, wherein the rotor assembly is directly connected to the end of the shaft.

[0075] 7. The motor according to any of the foregoing clauses, wherein no part of the stator assembly extends axially behind the rotor assembly.

[0076] 8. The motor according to any of the preceding clauses, further comprising: a motor shaft connected to an end of the shaft of the propulsion engine via an intermediate shaft member extending axially between the shaft and the motor shaft; and a generator bearing assembly comprising: a bearing support frame extending between the motor shaft and the engine stator component; and a generator bearing supporting the motor shaft, wherein the motor shaft rotates together with the shaft of the propulsion shaft within the generator bearing to rotate the rotor.

[0077] 9. The motor according to any of the preceding clauses further includes a cooling system comprising one or more cooling manifolds that direct coolant from a coolant source to a region adjacent to the stator and the rotor.

[0078] 10. An electric motor comprising: a stator assembly coupled to an engine stator component of a propulsion engine, the stator assembly including: a stator support assembly fixedly attached to the engine stator component; and a stator disposed on a support surface of the stator support assembly; and a rotor assembly including a rotor support structure directly connected to a shaft of the propulsion engine and a rotor attached to the rotor support structure, wherein: the rotor is disposed radially inside the stator such that the stator assembly circumferentially surrounds the rotor, and at least one of the following: the rotor rotates together with the shaft to generate an electrical signal, and the motor receives power from an external source to provide rotational energy to the shaft.

[0079] 11. The motor according to any of the preceding clauses, wherein the rotor support structure is directly connected to the end of the shaft of the propulsion engine via a removable connection, such that the rotor assembly can be independently removed from the propulsion engine.

[0080] 12. The motor according to any of the preceding clauses, wherein the rotor support structure is directly connected between the ends of the shaft of the propulsion engine.

[0081] 13. The motor according to any of the preceding clauses, wherein the rotor support structure extends from the end of the shaft in both the radial and axial directions to mechanically alter the inherent vibration mode of the shaft.

[0082] 14. The motor according to any of the preceding clauses, further comprising a motor control unit electrically connected to the stator, wherein the motor control unit is configured to actively adjust the motor load to affect the motor rotation, thereby suppressing vibration of the shaft.

[0083] 15. The motor according to any of the preceding clauses further includes a cooling system comprising one or more cooling manifolds that direct coolant from a coolant source to a region adjacent to the stator and the rotor.

[0084] 16. The motor according to any of the preceding clauses, wherein the wires extending from the stator are at least partially guided through the one or more cooling manifolds.

[0085] 17. An electric motor comprising: a stator assembly coupled to an engine stator component of a propulsion engine, the stator assembly including: a stator support assembly fixedly attached to the engine stator component; and a stator disposed on a support surface of the stator support structure; and a motor shaft coupled to an end of the shaft via an intermediate shaft member extending axially between the end of the shaft of the propulsion engine and the motor shaft; a bearing support frame extending from the propulsion engine, the bearing support frame including an axial portion extending in an axial direction; and a motor bearing extending from the bearing support frame. The axial portion extends radially to rotatably contact the motor shaft; a sealing member is axially disposed behind the motor bearing, the sealing member extending from the axial portion of the bearing support frame to the motor shaft; and a rotor assembly including: a rotor support structure connected to the motor shaft; and a rotor attached to the rotor support structure such that the rotor is disposed radially inside the stator, wherein at least one of the following occurs: the rotor rotates together with the shaft of the propulsion engine via the intermediate shaft member to generate an electrical signal, and the motor receives power from an external source to provide rotational energy to the shaft.

[0086] 18. The motor according to any of the preceding clauses, wherein the rotor support structure is connected to the motor shaft on the axial rear side of the generator bearing to facilitate removal of the rotor from the motor shaft.

[0087] 19. The motor according to any of the preceding clauses, further comprising a separation device attached to the propulsion engine, the separation device being positioned to axially overlap with the intermediate shaft member to separate the intermediate shaft member.

[0088] 20. The motor according to any of the preceding clauses, further comprising a seal extending between the bearing support frame and the motor shaft, the seal fluidly isolating the motor bearing from the bearing of the propulsion engine.

[0089] 21. An electric motor comprising: a stator assembly coupled to an engine stator component of a propulsion engine, the stator assembly including: a stator support assembly fixedly attached to the engine stator component; and a stator disposed on a support surface of the stator support assembly; and a motor shaft coupled to an end of a shaft of the propulsion engine via an intermediate shaft member extending axially between the end of the shaft and the motor shaft; a bearing support frame extending from the propulsion engine and defining a bearing cavity together with the motor shaft; a first motor bearing and a second motor bearing extending radially from the bearing support frame to rotatably contact the motor shaft; a sealing member axially disposed rearward of the motor bearing and extending from the bearing support frame to the motor shaft; a rotor support structure connected to the motor shaft; and a rotor attached to the rotor support structure, wherein the rotor rotates together with the motor shaft to exchange energy with the shaft of the propulsion engine.

[0090] 22. The motor according to any of the preceding clauses, wherein: the bearing cavity is defined by the bearing support frame together with the motor shaft, and the engine bearing of the propulsion engine is disposed within the bearing cavity.

[0091] 23. The motor according to any of the preceding clauses, further comprising: an oil supply line extending through the bearing support frame into a common reservoir at least partially defined between the bearing support frame and the motor shaft; a first oil nozzle extending from the oil supply line and disposed near the motor bearing; and a second oil nozzle extending from the oil supply line and disposed near the motor bearing.

[0092] 24. The motor according to any of the preceding clauses, wherein: the stator assembly includes a stator support arm connected to the engine stator component via an axial portion of the bearing support frame; and the oil supply line extends through the axial portion of the bearing support frame into the common reservoir.

[0093] 25. The motor according to any of the preceding clauses, further comprising an engine bearing support arm connected to the second engine stator component, the engine bearing support arm defining an engine bearing cavity together with the shaft of the propulsion engine.

[0094] 26. The motor according to any of the preceding clauses, further comprising a first sealing member and a second sealing member, the first sealing member and the second sealing member extending between the bearing support frame and the motor shaft to seal the bearing cavity.

[0095] 27. The motor according to any of the preceding clauses, further comprising: a first oil supply line extending through the bearing support frame into the bearing cavity; and a second oil supply line extending into the engine bearing cavity.

[0096] 28. The motor according to any of the preceding clauses further includes a separation device attached to the propulsion engine, the separation device being axially overlapped with the intermediate shaft member such that the separation device separates the intermediate shaft member when activated.

[0097] 29. The motor according to any of the preceding clauses, wherein the intermediate shaft member allows the motor shaft to move relative to the shaft of the propulsion engine in the axial and radial directions.

[0098] 30. The motor according to any of the preceding clauses, wherein the intermediate shaft includes a sleeve shaft having a first spline at a first end thereof and a second spline at a second end thereof, wherein the first spline and the second spline are inserted into openings at the ends of the shaft of the propulsion engine and the motor shaft to allow movement of the motor shaft in the axial direction and the radial direction.

[0099] 31. The motor according to any of the preceding clauses, wherein the entire rotor and the entire rotor support structure are disposed radially inside the stator assembly.

[0100] 32. The motor according to any of the preceding clauses, wherein the rotor support structure is removably connected to the end of the motor shaft, such that the rotor support structure and the rotor can be independently removed from the propulsion engine.

[0101] 33. The motor according to any of the preceding clauses, wherein the intermediate shaft includes a shear section configured to separate when placed under a predetermined shear load.

[0102] 34. A propulsion engine comprising: a core portion generating exhaust gas traveling in an axial direction; a turbine section coupled to a shaft, wherein the turbine section receives the exhaust gas and generates mechanical energy to rotate the shaft; a turbine frame attached to the turbine section, the turbine frame including: a housing coupled to the turbine section; and an inner hub supporting the shaft via a bearing assembly including an engine bearing supporting the shaft; and an electric motor including: a stator assembly including a stator support assembly attached to the inner hub and a stator attached to the stator support assembly; and a motor shaft coupled via an intermediate shaft member. The intermediate shaft member extends axially between the end of the shaft and the motor shaft, connected to the end of the shaft; a bearing support frame is attached to the inner hub and extends radially inward therefrom to define a bearing cavity extending between the bearing support frame and the motor shaft; a motor bearing extends radially from the bearing support frame to rotatably contact the motor shaft; and a rotor assembly includes: a rotor support structure connected to the motor shaft; and a rotor attached to the rotor support structure and extending radially inward of the stator, wherein the rotor rotates with the shaft via the intermediate shaft member to exchange energy with the shaft.

[0103] 35. The propulsion engine according to any of the preceding clauses, wherein: the turbine frame further includes a plurality of struts extending between the housing and the inner hub, and at least one of the plurality of struts defines an internal cavity having cooling ducts disposed therein.

[0104] 36. The propulsion engine according to any of the preceding clauses, wherein the motor further includes a cooling system comprising a stator manifold for supplying coolant from a coolant source to the stator assembly and the rotor assembly.

[0105] 37. The propulsion engine according to any of the preceding clauses, wherein the intermediate shaft member and the motor shaft are integrated components.

[0106] 38. The propulsion engine according to any of the preceding clauses further includes a separation device that overlaps axially with the intermediate shaft member, such that the separation device separates the intermediate shaft member when activated.

[0107] 39. The propulsion engine according to any of the preceding clauses, wherein the intermediate shaft member allows the motor shaft to move relative to the shaft of the propulsion engine in the axial and radial directions.

[0108] 40. The propulsion engine according to any of the preceding clauses further includes a sealing member extending between the bearing support frame and the motor shaft to seal the bearing cavity.

[0109] It will be apparent to those skilled in the art that various modifications and variations can 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 to the various embodiments described herein, provided that such modifications and variations fall within the scope of the appended claims and their equivalents.

Claims

1. An electric machine characterized in that, includes: a stator assembly coupled to an engine stator component of a propulsion engine, the stator assembly including: a stator support assembly fixedly attached to the engine stator component; and a stator disposed on a support surface of the stator support assembly; and a rotor assembly including a rotor support structure connected to a shaft of the propulsion engine and a rotor attached to the rotor support structure such that the rotor is disposed radially inward of the stator, wherein the rotor exchanges rotational energy with the shaft to operate as a motor or generator, wherein the rotor support structure extends from the end of the shaft in a radial direction and an axial direction to mechanically alter the natural vibration modes of the shaft.

2. The electric machine of claim 1, wherein, wherein the stator assembly circumferentially surrounds the rotor assembly such that the rotor assembly is disposed radially between the shaft and the stator assembly.

3. The electric machine of claim 2, wherein, wherein the stator support assembly includes a stator support arm extending parallel to the shaft in an axial direction, the stator support arm defining the support surface, wherein the stator support arm is at least as long in the axial direction as the rotor assembly such that the entire rotor assembly is disposed in a rotor cavity bounded by the stator support arm and the stator support arm isolates the propulsion engine from the rotor assembly.

4. The electric machine of claim 3, wherein, further including: an electrical connection device coupled to the stator support assembly; and an electrical wire extending from the stator to the electrical connection device.

5. The electric machine of claim 1, wherein, further including an electric machine control unit electrically connected to the stator, wherein the electric machine control unit is configured to switch operation of the electric machine between a generator mode in which power is generated by rotation of the shaft and a motor mode in which the stator adds rotational energy to the shaft.

6. The electric machine of claim 1, wherein, wherein the rotor assembly is directly connected to an end of the shaft.

7. The electric machine of claim 6, wherein, wherein no part of the stator assembly extends axially behind the rotor assembly.

8. The electric machine of claim 1, wherein, further including: an electric machine shaft coupled to an end of the shaft of the propulsion engine via an intermediate shaft member extending axially between the shaft and the electric machine shaft; and an electric machine bearing assembly including: a bearing support frame extending between the electric machine shaft and the engine stator component; and an electric machine bearing supporting the electric machine shaft, wherein the electric machine shaft rotates within the electric machine bearing with the shaft of the propulsion shaft to rotate the rotor.

9. The electric machine of claim 1, wherein, further including a cooling system including one or more cooling manifolds directing coolant from a source of coolant to areas proximate the stator and the rotor.

10. An electric machine characterized by includes: a stator assembly coupled to an engine stator component of a propulsion engine, the stator assembly including: a stator support assembly fixedly attached to the engine stator component; and a stator disposed on a support surface of the stator support assembly; and a rotor assembly including a rotor support structure connected to a shaft of the propulsion engine and a rotor attached to the rotor support structure such that the rotor is disposed radially inward of the stator, wherein the rotor exchanges rotational energy with the shaft to operate as a motor or generator, wherein the rotor support structure extends from the end of the shaft in a radial direction and an axial direction to mechanically alter the natural vibration modes of the shaft. wherein the stator assembly circumferentially surrounds the rotor assembly such that the rotor assembly is disposed radially between the shaft and the stator assembly. wherein the stator support assembly includes a stator support arm extending parallel to the shaft in an axial direction, the stator support arm defining the support surface, wherein the stator support arm is at least as long in the axial direction as the rotor assembly such that the entire rotor assembly is disposed in a rotor cavity bounded by the stator support arm and the stator support arm isolates the propulsion engine from the rotor assembly. further including: an electrical connection device coupled to the stator support assembly; and an electrical wire extending from the stator to the electrical connection device. further including an electric machine control unit electrically connected to the stator, wherein the electric machine control unit is configured to switch operation of the electric machine between a generator mode in which power is generated by rotation of the shaft and a motor mode in which the stator adds rotational energy to the shaft. wherein the rotor assembly is directly connected to an end of the shaft. wherein no part of the stator assembly extends axially behind the rotor assembly. further including: an electric machine shaft coupled to an end of the shaft of the propulsion engine via an intermediate shaft member extending axially between the shaft and the electric machine shaft; and an electric machine bearing assembly including: a bearing support frame extending between the electric machine shaft and the engine stator component; and an electric machine bearing supporting the electric machine shaft, wherein the electric machine shaft rotates within the electric machine bearing with the shaft of the propulsion shaft to rotate the rotor. further including a cooling system including one or more cooling manifolds directing coolant from a source of coolant to areas proximate the stator and the rotor. A rotor assembly including a rotor support structure directly connected to a shaft of the propulsion engine and a rotor attached to the rotor support structure, wherein: the rotor is disposed radially inward of the stator such that the stator assembly circumferentially surrounds the rotor, wherein the rotor support structure extends from the end of the shaft in a radial direction and an axial direction to mechanically alter a natural vibration mode of the shaft, and at least one of: the rotor rotates with the shaft to generate an electrical power signal, and the motor receives electrical power from an external source to provide rotational energy to the shaft.

11. The electric machine of claim 10, wherein, wherein the rotor support structure is directly connected to the shaft of the propulsion engine via a removable connection such that the rotor assembly is independently removable from the propulsion engine.

12. The electric machine of claim 10, wherein, wherein the rotor support structure is directly connected to the shaft between ends of the shaft of the propulsion engine.

13. The electric machine of claim 10, wherein, further comprising a motor control unit electrically connected to the stator, wherein the motor control unit is configured to actively adjust motor load to influence motor rotation to dampen vibration of the shaft.

14. The electric machine of claim 10, wherein, further comprising a cooling system including one or more cooling manifolds that direct coolant from a coolant source to an area proximate the stator and the rotor.

15. The electric machine of claim 14, wherein, wherein electrical wires extending from the stator are at least partially routed through the one or more cooling manifolds.

16. An electric machine characterized by including: a stator assembly coupled to an engine stator component of a propulsion engine, the stator assembly including: a stator support assembly fixedly attached to the engine stator component; and a stator disposed on a support surface of the stator support assembly; and a motor shaft coupled to an end of a shaft of the propulsion engine via an intermediate shaft member extending axially between the end of the shaft and the motor shaft; a bearing support frame extending from the propulsion engine, the bearing support frame including an axial portion extending in an axial direction; a motor bearing extending radially from the axial portion of the bearing support frame to rotatably contact the motor shaft; a seal member disposed axially aft of the motor bearing, the seal member extending from the axial portion of the bearing support frame to the motor shaft; and a rotor assembly including: a rotor support structure connected to the motor shaft; and a rotor attached to the rotor support structure such that the rotor is disposed radially inward of the stator, wherein the rotor support structure extends from the end of the shaft in a radial direction and an axial direction to mechanically alter a natural vibration mode of the shaft, wherein at least one of: the rotor rotates with the shaft via the intermediate shaft member to generate an electrical power signal, and the motor receives electrical power from an external source to provide rotational energy to the shaft.

17. The electric machine of claim 16, wherein, wherein the rotor support structure is connected to the motor shaft at an axially aft side of the motor bearing to facilitate removal of the rotor from the motor shaft.

18. The electric machine of claim 16, wherein, further comprising a separation device attached to the propulsion engine, the separation device positioned in axial overlap with the intermediate shaft member to separate the intermediate shaft member.

19. The electric machine of claim 16, wherein, further comprising a seal extending between the bearing support frame and the motor shaft, the seal isolating the motor bearing from a bearing fluid of the propulsion engine.

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