Turbine power generation power structure with starting function

Abstract

The invention discloses a turbine power generation power structure with a starting function. The turbine power generation power structure aims at solving the problems that an existing double-rotor eddy current power system is complex in layout, large in weight, high in transmission loss, poor in generator working environment, low in reliability and the like. The structure comprises a double-rotor turbine shaft engine, a starting generator, a separation fence and a main generator. The starting generator and the main generator are both integrally arranged on the air inlet side of the double-rotor turbine shaft engine and connected with corresponding output shafts of the double-rotor turbine shaft engine in a speed reducer-free direct connection mode. The isolation gate is connected between the starting generator and the main generator and used for isolating magnetic field interference of the starting generator and the main generator. Through the integrated layout and the direct connection transmission design, the size and weight of the system are reduced, the transmission efficiency and reliability are improved, the cooling effect of the generator is optimized through cold air on the air inlet side, the low-altitude economic turbine hybrid power requirement is met, the system can be rapidly matched with an existing double-rotor turboshaft engine, and the development period is shortened.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of turbine power generation systems, in particular to a turbine power generation structure with starting function. BACKGROUND

[0002] Traditional turboshaft engines mainly provide power for helicopters, and the power shaft output needs to pass through the main reducer to realize steering and speed reduction, thereby driving the helicopter propeller to work, so it is usually not used for power generation. However, ground turbine engines are basically used for power generation. For example, when a ground gas turbine is used for power generation, the output shaft of the engine needs to be gear-reduced, and a heavy gear reduction box must be provided. Since there is no strict restriction on space and weight in the ground scene, this problem has not constituted a core obstacle.

[0003] With the rapid development of low-altitude economy, turbine hybrid power has become a mainstream trend, and needs to be modified on the basis of turboshaft engines to meet the power generation requirements. The traditional power generation mode relies on the design of the gear reduction box, which greatly reduces the power-to-weight ratio of the power system, so the domestic and foreign markets are gradually shifting to direct connection routes, that is, the output shaft of the engine is directly connected to the main shaft of the generator, maintaining the same speed, to avoid the disadvantages of the gear reduction box.

[0004] At present, there are mainly two kinds of mainstream turboshaft direct connection power structures: one is a single-shaft turboshaft engine structure, but its power level is low and the overall efficiency is poor, and it is only suitable for small power scenarios; the other is a double-shaft turboshaft + rear-mounted main generator structure, that is, the main generator is arranged on the exhaust side of the turbine engine (a reducer may still be provided between the engine and the main generator), and an accessory gear box containing a starter is arranged on the intake side of the engine to meet the starting requirements. This structure has many defects:

[0005] 1. The starter and the generator are arranged on the front and rear sides, respectively, and a split structure is adopted, which greatly increases the complexity of the overall space layout (including structure, connection and wiring), not only occupies redundant space, but also increases the weight of the system; and the power conversion is realized through the reduction transmission accessories in the gear box, which not only produces additional transmission loss, but also reduces the system reliability.

[0006] 2. The main generator is arranged on the exhaust side, which will interfere with the exhaust layout of the engine; at the same time, high-temperature-resistant insulation materials are required to insulate and seal the engine body and the main generator in the high-temperature environment on the exhaust side, even so, the main generator is still in a harsh high-temperature environment, and the service life and reliability are seriously affected. If the main generator needs to be cooled by air or sealed, a complex air duct needs to be additionally arranged to introduce air from the front end or the outside of the engine, further increasing the complexity of the system. SUMMARY

[0007] To address the problems of complex layout, heavy weight, high transmission loss, harsh generator operating environment, and low reliability of existing dual-rotor eddy electric power systems, this invention provides a turbine generator power structure with start-up function. Through integrated layout and direct drive design, the system performance is optimized to meet the demand for low-altitude economical turbine hybrid power.

[0008] To achieve the above objectives, the present invention employs the following technical means:

[0009] A turbine-powered generator structure with a starter generator function includes a dual-rotor turboshaft engine, a starter generator, an isolation grid, and a main generator;

[0010] Both the starter generator and the main generator are integrated on the intake side of the dual-rotor turboshaft engine and are directly connected to the corresponding output shaft of the dual-rotor turboshaft engine in a gearless direct connection manner; the isolation barrier is connected between the starter generator and the main generator to isolate magnetic field interference between the two.

[0011] Preferably, the magnetic circuit structures of the starter generator and the main generator are selected independently, and include at least any of the following combinations: the starter generator is an axial flux motor and the main generator is a radial flux motor with an inner rotor and an outer stator; or the starter generator is an axial flux motor and the main generator is a radial flux motor with an outer rotor and an inner stator; or both the starter generator and the main generator are axial flux motors; or both the starter generator and the main generator are radial flux motors.

[0012] Preferably, the dual-rotor turboshaft engine includes: a free turbine output shaft, a main shaft locking nut, an engine main shaft, a core rotor, and a free turbine rotor;

[0013] The free turbine output shaft and the engine main shaft are arranged in a concentric sleeve, and the free turbine output shaft is connected to the free turbine rotor;

[0014] The engine main shaft is connected to the core rotor, and the core rotor is connected to the free turbine rotor via a pneumatic means.

[0015] Preferably, the starter generator includes a starter generator stator assembly and a starter generator rotor assembly, wherein the starter generator rotor assembly is connected to the engine main shaft for transmitting torque and achieving axial positioning.

[0016] Preferably, the generator rotor assembly is connected to the engine main shaft via a torque-transmitting positioning seat;

[0017] The torque transmission positioning seat is connected to the engine main shaft via a spline to transmit torque, and achieves axial positioning via a shaft shoulder.

[0018] Preferably, the main generator includes: a main generator housing, a main generator stator assembly, a main generator main shaft, bearings, and a main generator rotor assembly;

[0019] The main generator stator assembly is fixedly installed inside the main generator housing;

[0020] The main generator shaft is rotatably supported on the main generator housing by bearings, and the main generator shaft is connected to the free turbine output shaft by a spline.

[0021] The main generator rotor assembly is coaxially arranged and connected to the main generator main shaft, rotates together with the main generator main shaft, and maintains a working air gap with the main generator stator assembly.

[0022] Preferably, the main generator housing is provided with a main generator cooling channel for introducing cold air from the intake side to cool the main generator.

[0023] Preferably, the outer periphery of the main generator housing is provided with main generator heat dissipation fins.

[0024] Preferably, the main generator rotor assembly is provided with a first positioning shoulder and a second positioning shoulder at both axial ends for axial positioning.

[0025] The second positioning shoulder is provided with a preset axial movement clearance.

[0026] Preferably, an airflow hole is provided at one end of the main generator rotor assembly near the first positioning shoulder, and the airflow hole communicates with the keyway gap of the main generator shaft to form an airflow channel.

[0027] The present invention has the following beneficial effects:

[0028] 1. Integrated layout optimization significantly reduces system size and weight.

[0029] Compared to the traditional split layout of "starter motor in front + generator in rear", this invention integrates the starter and generator with the main generator through a concentric integrated design and arranges them on the intake side of the dual-rotor turbine engine. Combined with the compact partition structure of the isolation grille, it completely eliminates the redundant space occupation and complex connection wiring caused by the front and rear split layout.

[0030] This design simplifies the overall structural layout and reduces the number of auxiliary components such as pipes and supports. On the other hand, it avoids the heavy-duty heat insulation and sealing structure required for the exhaust-side generator, which significantly reduces the overall weight of the power system compared to the traditional structure and significantly improves the power-to-weight ratio. It can fully meet the core requirements of lightweight and compact design for low-altitude aircraft, portable power generation equipment, etc.

[0031] 2. Direct drive without a speed reducer improves efficiency and enhances reliability.

[0032] The starter generator is directly connected to the engine main shaft via a torque locating seat, and the main generator is directly connected to the free turbine output shaft via the main generator main shaft. Both adopt a spline transmission method without a reducer, which fundamentally solves the drawbacks of traditional gear reducers.

[0033] Firstly, it eliminates frictional and meshing clearance losses in the gear transmission process, significantly improving transmission efficiency compared to traditional structures and greatly increasing the conversion rate of electrical energy output. Secondly, it reduces the gearbox, a vulnerable core component, thereby lowering the failure points of the transmission system. At the same time, the shoulder positioning and spline meshing design of the torque transmission positioning seat ensures accurate and unbiased torque transmission, further improving the stability and reliability of the system operation and significantly reducing the failure rate.

[0034] 3. The intake-side layout design optimizes the operating environment and extends equipment life.

[0035] This invention moves the main generator to the intake side, completely eliminating the high-temperature problems associated with traditional exhaust-side layouts and creating multiple operational advantages:

[0036] More rational exhaust layout: freeing up space on the exhaust side allows the engine exhaust passage to be designed according to the optimal aerodynamic path, avoiding interference from the generator to the exhaust airflow, and indirectly improving engine power performance;

[0037] More efficient cooling and protection: No complex heat insulation structure is required. It can directly utilize the ambient temperature cold air on the intake side. The airflow channel formed by the cooling channel, airflow hole and the keyway gap of the main shaft, combined with the heat dissipation fins, achieves all-round heat dissipation. The operating temperature of the main generator is effectively controlled, which is far superior to the traditional exhaust side layout. It effectively avoids the aging damage of high temperature to core components such as coils and permanent magnets, and significantly extends the service life of the equipment.

[0038] Easier sealing and maintenance: The cleanliness and temperature of the intake side environment are better than those of the exhaust side, which simplifies the sealing design of the generator and facilitates the inspection and maintenance of components such as generators and bearings, reducing operation and maintenance costs.

[0039] 4. Auxiliary structures provide collaborative protection, ensuring long-term stable operation.

[0040] The auxiliary structure design of this invention specifically addresses key issues such as thermal expansion, magnetic field interference, and frictional loss during high-speed power generation, ensuring the long-term stable operation of the system.

[0041] Reliable magnetic field isolation: The isolation fence is made of non-magnetic material, which can effectively block electromagnetic interference between the generator and the main generator, avoid electromagnetic disturbance from affecting the power generation accuracy, and ensure the power quality when the two generators are running synchronously.

[0042] Thermal expansion adaptive: The axial movement clearance reserved in the main generator rotor assembly can accurately compensate for the thermal expansion during high-speed operation, avoid bearing wear caused by over-positioning, and help the rotor automatically align with the magnetic center, reducing the risk of vibration and rotor rubbing caused by unilateral magnetic pull.

[0043] 5. Highly adaptable, shortening the research and development and application cycle.

[0044] This invention is based on the existing dual-rotor turbine shaft engine structure design. It does not require major modifications to the engine body. It can flexibly adjust the generator power specifications, connection methods and auxiliary structural details according to the power output and torque transmission method of the existing engine, and quickly achieve optimized matching of mechanical structure and performance.

[0045] This flexibility and adaptability can significantly shorten the development cycle of new products and reduce R&D costs. At the same time, it facilitates the upgrading and transformation of existing turboshaft power systems. It can be widely used in various scenarios such as small low-altitude aircraft, medium and large logistics drones, and field emergency power generation equipment, covering multiple power level requirements and has extremely strong market adaptability. Attached Figure Description

[0046] Figure 1 This is a cross-sectional view of the structure of the present invention;

[0047] Figure 2 This is a schematic diagram of the structure of the dual-rotor turboshaft engine of the present invention;

[0048] Figure 3 This is a cross-sectional view of the structure of the generator and the main generator of the present invention;

[0049] Figure 4 This is a schematic diagram of the main generator housing of the present invention;

[0050] Figure 5 This is a structural cross-sectional view of the main generator shaft of the present invention;

[0051] Figure 6 This is a schematic diagram of the main generator rotor assembly of the present invention;

[0052] In the attached figures, the following labels are used:

[0053] Dual-rotor turbine shaft engine 1, free turbine output shaft 101, main shaft locking nut 102, torque transmission positioning seat 103, engine main shaft 104, core engine rotor 105, free turbine rotor 106;

[0054] Generator 2, generator stator assembly 201, generator rotor assembly 202;

[0055] 3. Isolation fence;

[0056] Main generator 4, main generator housing 401, main generator stator assembly 402, main generator main shaft 403, bearing 404, main generator rotor assembly 405, main generator cooling channel 406, main generator heat dissipation fins 407, first positioning shoulder 408, axial movement clearance 409, second positioning shoulder 410, airflow hole 411. Detailed Implementation

[0057] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0058] like Figures 1-6 As shown, a turbine power generation structure with start-up function includes a dual-rotor turbine shaft engine 1, a starter generator 2, an isolation grid 3, and a main generator 4. The starter generator 2 and the main generator 4 are both integrated on the intake side of the dual-rotor turbine shaft engine 1 and are respectively connected to the corresponding output shaft of the dual-rotor turbine shaft engine 1 in a direct connection without a reducer. The isolation grid 3 is connected between the starter generator 2 and the main generator 4 to isolate the magnetic field interference between the two.

[0059] Furthermore, the magnetic circuit structures of the starter generator 2 and the main generator 4 are selected independently, and include at least one of the following combinations: the starter generator 2 is an axial flux motor and the main generator 4 is a radial flux motor with an inner rotor and an outer stator; or the starter generator 2 is an axial flux motor and the main generator 4 is a radial flux motor with an outer rotor and an inner stator; or both the starter generator 2 and the main generator 4 are axial flux motors; or both the starter generator 2 and the main generator 4 are radial flux motors. This configuration provides high flexibility and optimization space for the design of the entire turbine power generation system.

[0060] Furthermore, the dual-rotor turboshaft engine 1 includes a free turbine output shaft 101, a main shaft locking nut 102, an engine main shaft 104, a core engine rotor 105, and a free turbine rotor 106; the free turbine output shaft 101 and the engine main shaft 104 are arranged in a concentric sleeve configuration, and the free turbine output shaft 101 is connected to the free turbine rotor 106; the engine main shaft 104 is connected to the core engine rotor 105, and the core engine rotor 105 and the free turbine rotor 106 are connected pneumatically to achieve power transmission.

[0061] The starter generator 2 includes a starter generator stator assembly 201 and a starter generator rotor assembly 202. The starter generator rotor assembly 202 is connected to the engine main shaft 104 through a torque transmission positioning seat 103. The torque transmission positioning seat 103 is connected to the engine main shaft 104 through a spline to transmit torque and achieves axial positioning through a shaft shoulder, ensuring that the starter generator 2 and the engine main shaft 104 operate synchronously and are stably positioned.

[0062] The main generator 4 includes a main generator housing 401, a main generator stator assembly 402, a main generator main shaft 403, a bearing 404, and a main generator rotor assembly 405. The main generator stator assembly 402 is fixedly installed inside the main generator housing 401. The main generator main shaft 403 is rotatably supported on the main generator housing 401 through the bearing 404 and is connected to the free turbine output shaft 101 through a spline. The main generator rotor assembly 405 is coaxially connected to the main generator main shaft 403 and rotates synchronously, maintaining a preset working air gap with the main generator stator assembly 402 to ensure power generation efficiency.

[0063] To optimize cooling, a main generator cooling channel 406 is provided on the main generator housing 401, which can introduce cold air from the intake side to directly cool the main generator; main generator heat dissipation fins 407 are provided on the outer periphery of the main generator housing 401 to increase the heat dissipation area and improve heat dissipation efficiency.

[0064] The main generator rotor assembly 405 is provided with a first positioning shoulder 408 and a second positioning shoulder 410 at both ends of the axial direction to achieve axial positioning. A preset axial movement clearance 409 is provided at the second positioning shoulder 410 to compensate for thermal expansion during operation, avoid over-positioning and bearing wear, and at the same time enable the rotor to freely align with the magnetic center and electromagnetic balance, reducing the risk of vibration or rotor rubbing caused by unilateral magnetic pull.

[0065] An airflow hole 411 is provided at one end of the main generator rotor assembly 405 near the first positioning shoulder 408. The airflow hole 411 is connected to the keyway gap of the main generator main shaft 403 to form an airflow channel, which can achieve pressure balance and auxiliary cooling, and further enhance the service life of the motor.

[0066] It should be noted that the connection and positioning method of the components in this invention is not limited to spline connection; other coupling and positioning methods such as couplings can also be used. Spline connection is only a preferred solution in specific embodiments. The bearing 404 can be lubricated with grease or oil as required. If oil lubrication is used, an oil flow path channel needs to be reserved in the corresponding stator structure.

[0067] Working principle

[0068] The core of this turbine power generation structure lies in the integrated, direct-connected dual-generator collaborative working mode. Its working principle can be divided into three main stages: start-up, power generation, and cooling and protection, which are closely related to the power output characteristics of the dual-rotor turbine shaft engine.

[0069] I. Start-up Phase: The generator acts as an electric motor to drive the engine to start.

[0070] Power supply and drive: When the system starts, an external power source supplies power to generator 2. At this time, the generator operates as a motor.

[0071] Torque transmission: The torque generated by the generator rotor assembly 202 is transmitted directly and without deceleration to the engine main shaft 104 through the torque transmission positioning seat 103 and its spline connection.

[0072] The engine main shaft 104 is rigidly connected to the core engine rotor 105. Therefore, the torque output by the starter generator directly drives the core engine rotor 105 to start rotating, completing the engine's compression, ignition, and combustion initialization processes.

[0073] Pneumatic linkage: When the core rotor 105 reaches a certain speed, the generated gas flow begins to drive the free turbine rotor 106 to rotate, and the engine enters a self-sustaining operation state. At this time, the external power supply is disconnected.

[0074] II. Power Generation Phase: Dual generators operate independently, coordinating for efficient power generation.

[0075] Once the dual-rotor turboshaft engine 1 is running stably, the system enters the power generation stage. Both the starter generator and the main generator switch to power generation mode, obtaining mechanical energy from different power sources and converting it into electrical energy.

[0076] Start the generator to generate electricity:

[0077] Power source: After the engine is running stably, the core rotor 105 continuously outputs mechanical energy through the engine main shaft 104.

[0078] Energy conversion: The starter generator 2 is directly connected to the engine main shaft 104. At this time, the mechanical energy of the core machine drives the starter generator rotor assembly 202 to rotate in reverse, and the starter generator switches to power generation mode, converting part of the mechanical energy into electrical energy to power onboard equipment or recharge the starter battery.

[0079] Main generator generates electricity:

[0080] Power source: The free turbine rotor 106 is driven to rotate by the gas discharged from the core machine and outputs independent, typically low-speed mechanical energy through the free turbine output shaft 101.

[0081] Energy Conversion: The free turbine output shaft 101 is directly connected to the main generator main shaft 403 via a spline, driving the main generator rotor assembly 405 to rotate. The rotor moves relative to the fixed main generator stator assembly 402, cutting magnetic field lines, thereby efficiently converting most of the mechanical energy extracted by the free turbine into electrical energy, which serves as the main power output of the system.

[0082] Magnetic field isolation and independent operation:

[0083] The isolation barrier 3 located between the two generators is made of non-magnetic material, which effectively isolates the alternating magnetic field generated by the starter generator 2 and the main generator 4 during operation, prevents electromagnetic interference between the two, and ensures the power quality and control stability of their respective generators.

[0084] III. Cooling, Thermal Management and Stable Operation Guarantee

[0085] Through its unique layout and design, this structure simultaneously achieves efficient heat dissipation and operational protection during operation.

[0086] Advantages of intake-side cooling: The main generator 4 is located on the intake side of the engine and is directly exposed to the ambient temperature intake airflow.

[0087] Active cooling: Cold air is introduced through the main generator cooling channel 406 to directly cool heat-generating components such as the stator assembly.

[0088] Passive cooling: The main generator cooling fins 407 increase the heat dissipation area of ​​the casing, improving the efficiency of natural convection cooling.

[0089] Internal airflow circulation: The airflow holes 411 on the rotor assembly and the keyway gap of the main shaft form an internal airflow channel, which promotes air circulation by utilizing the centrifugal effect of the rotor rotation, thereby achieving pressure balance and auxiliary cooling inside the rotor.

[0090] Thermal expansion adaptive:

[0091] The preset axial movement clearance 409 provided on the main generator rotor assembly 405 allows the rotor to move slightly axially when it generates heat and expands axially during high-speed operation.

[0092] This design avoids over-positioning wear of the bearing 404 due to thermal expansion, while allowing the rotor to automatically find and stabilize at the magnetic center under the action of magnetic force, reducing unbalanced magnetic pull, effectively preventing vibration and rotor rubbing risks, and ensuring long-term operational reliability.

[0093] Summary of working principles

[0094] The working principle of this power structure achieves a closed loop of "one machine for two purposes, direct connection for high efficiency, and environmental friendliness":

[0095] During startup, the generator acts as an electric motor, directly driving the engine core to start.

[0096] During operation, the starter generator and the main generator are directly connected to the core shaft of the engine and the output shaft of the free turbine, respectively, and independently and synchronously convert the mechanical energy of shaft systems with different speeds into electrical energy.

[0097] Throughout the process, thanks to the excellent environment on the intake side, the efficient direct drive, the cooling system that combines active and passive cooling, and the targeted design for thermal management and electromagnetic compatibility, the entire system achieves high power generation efficiency, high operational reliability, and long service life while remaining compact and lightweight.

[0098] This design cleverly utilizes the power output characteristics of a dual-rotor engine, and through integrated layout and direct connection, optimizes the energy transfer path, significantly improving the overall performance of the turbine power generation system.

[0099] Example 1

[0100] Small low-altitude aircraft compatible (100-200kW power rating)

[0101] I. Adapted Scenarios

[0102] This embodiment is applicable to equipment with extremely high lightweight requirements, such as small electric helicopters and low-altitude flight platforms. It needs to balance power output, structural compactness and cost control. The operating environment is mainly at normal temperature and low altitude, and the extreme requirements for heat dissipation are relatively low.

[0103] II. Structural Details

[0104] 1. Dual-rotor turboshaft engine 1: A small and lightweight dual-rotor turboshaft engine is selected. The free turbine output shaft 101 and the engine main shaft 104 are concentric shaft structures with shaft diameters of 35mm and 25mm respectively. They are made of high-strength aluminum alloy to balance weight reduction and torque transmission requirements. The aerodynamic coupling gap between the core rotor 105 and the free turbine rotor 106 is controlled at 0.8mm to improve power transmission efficiency.

[0105] 2. Starter Generator 2: The power specification is 20kW. The starter generator rotor assembly 202 is connected to the engine main shaft 104 via an involute spline (spline module 2.5, number of teeth 18) through the torque transmission positioning seat 103. The torque transmission positioning seat 103 is made of 45 steel and heat treated. The axial positioning accuracy of the shaft shoulder is controlled within ±0.02mm. The starter generator stator assembly 201 is fixed to the engine intake side end cover, and the working air gap between it and the rotor assembly is set to 0.5mm.

[0106] 3. Main generator 4: The power specification is 150kW. The main generator housing 401 is made of cast aluminum, which is 30% lighter than the steel housing. The main generator cooling channel 406 adopts a ring array design with 8 through holes of 8mm in diameter, which are evenly distributed around the circumference of the housing, allowing direct introduction of cold air from the intake side. The main generator heat dissipation fins 407 are integrally cast, with a height of 15mm, a thickness of 3mm, and a spacing of 10mm, which increases the heat dissipation area while simplifying the processing technology.

[0107] 4. Positioning and Lubrication Design: The axial clearance 409 of the main generator rotor assembly 405 is set to 0.6mm to accommodate the thermal expansion of a small motor; the bearing 404 is a deep groove ball bearing (model 6208) lubricated with lithium-based grease, eliminating the need for additional oil flow paths and simplifying the structure; two airflow holes 411 with a diameter of 4mm are opened at the end of the main generator rotor assembly 405 near the first positioning shoulder 408, forming a simple airflow channel with the keyway gap of the main shaft to meet the basic pressure balance and cooling requirements.

[0108] 5. Isolation fence 3: Made of 5mm thick stainless steel non-magnetic plate with anodized surface, it is fixed to the flange between generator 2 and main generator 4 by bolts. It weighs only 0.8kg, effectively isolating magnetic field interference while controlling the overall weight.

[0109] III. Work Process and Results

[0110] During startup, generator 2 drives the engine main shaft 104 according to a preset schedule, and switches to power generation mode after disengaging at 1800 r / min. During power generation, the engine core drives the free turbine output shaft 101 to rotate at 12000 r / min, while the main generator 4 generates electricity synchronously and generator 2 provides auxiliary power. The total output power of the two generators can reach 170 kW. The overall power system of this embodiment weighs only 85 kg, and the power-to-weight ratio is improved by 25% compared to the traditional split structure. The intake-side cooling can keep the main generator's operating temperature below 60°C, meeting the long-term operational requirements of small low-altitude aircraft.

[0111] Example 2

[0112] Medium-power fixed-wing equipment compatible (500-800kW power rating)

[0113] I. Adapted Scenarios

[0114] This embodiment is applicable to medium and large low-altitude logistics drones, short-distance commuter fixed-wing aircraft and other equipment. It needs to take into account high power output, high-speed operation stability and adaptability to complex working conditions. The operating environment may involve high temperature, high humidity and small vibration scenarios.

[0115] II. Structural Details

[0116] 1. Dual-rotor turboshaft engine 1: A medium-power dual-rotor turboshaft engine is selected. The free turbine output shaft 101 and the engine main shaft 104 have diameters of 50mm and 38mm respectively. They are made of chromium-molybdenum alloy steel and the surface is carburized to improve wear resistance and fatigue strength. The core rotor 105 and the free turbine rotor 106 are optimized through aerodynamic blade design to improve power transmission efficiency under high-speed conditions.

[0117] 2. Starter Generator 2: The power specification is 50kW. The starter generator rotor assembly 202 and the torque transmission positioning seat 103 are connected by a shrink sleeve and spline to transmit torque, which not only ensures the reliability of torque transmission, but also facilitates disassembly and maintenance. An elastic washer is added at the shoulder of the torque transmission positioning seat 103 and the engine main shaft 104 to buffer the impact of vibration on positioning accuracy.

[0118] 3. Main generator 4: The power specification is 700kW. The main generator housing 401 is made of high-strength cast iron with an internal reinforcing rib structure to improve vibration resistance. The main generator cooling channel 406 adopts a spiral design and is connected to the inside of the housing. At the same time, a filter screen is installed at the inlet of the cooling channel to prevent impurities from entering. The main generator heat dissipation fins 407 are detachable copper fins, which are fixed to the housing with bolts for easy maintenance and replacement. The heat dissipation efficiency is 40% higher than that of cast aluminum fins.

[0119] 4. Positioning and Lubrication Design: The axial clearance 409 of the main generator rotor assembly 405 is set to 0.8mm to meet the thermal expansion requirements of medium-power motors; the bearing 404 is an angular contact ball bearing (model 7215) with lubricating oil. Dedicated lubricating oil flow paths are reserved in the main generator housing 401 and the engine intake side housing. The lubricating oil flow rate is controlled at 40L / min to ensure lubrication and cooling effects under high-speed operation; the airflow hole 411 has four 6mm diameter through holes, symmetrically distributed on the rotor end face to enhance pressure balance and internal cooling.

[0120] 5. Isolation fence 3: Made of 8mm thick titanium alloy non-magnetic plate, weighing 1.5kg, it has both high strength and corrosion resistance. It is fixed to the flange surface by welding, which improves the stability under vibration conditions. The magnetic field isolation efficiency can reach more than 98%.

[0121] III. Work Process and Results

[0122] During startup, generator 2 drives the main shaft of engine 104 to a speed of 2200 r / min, disengaging it and switching to power generation mode. During power generation, the speed of the free turbine output shaft 101 stabilizes at 15000 r / min, and the total output power of the main generator 4 and generator 2 can reach 750 kW. The lubrication system and spiral cooling channel work together to keep the main generator's operating temperature below 75℃, ensuring stable output even in high-temperature environments of 35℃. This embodiment has strong overall vibration resistance, is suitable for high-speed flight conditions of fixed-wing equipment, and its reliability is improved by 30% compared to traditional structures.

[0123] Example 3

[0124] High-power portable generator adapter (1000-1500kW power rating)

[0125] I. Adapted Scenarios

[0126] This embodiment is applicable to scenarios such as backup power supply for low-altitude work platforms and emergency power generation equipment in the field. It needs to meet the requirements of continuous high power output, adaptability to harsh environments and long-term operational stability, and has extremely high requirements for heat dissipation, sealing and torque transmission reliability.

[0127] II. Structural Details

[0128] 1. Dual-rotor turboshaft engine 1: A high-power dual-rotor turboshaft engine is selected. The free turbine output shaft 101 and the engine main shaft 104 have shaft diameters of 65mm and 50mm respectively. They are made of nickel-based high-temperature alloy material, which can withstand the strength loss under high-temperature conditions. The free turbine output shaft 101 and the free turbine rotor 106 are fixed by welding. The engine main shaft 104 and the core rotor 105 are connected by interference fit to improve the reliability of torque transmission.

[0129] 2. Starter Generator 2: The power specification is 100kW. The starter generator rotor assembly 202 is connected to the torque transmission positioning seat 103 by a coupling (a diaphragm coupling is selected to compensate for installation deviation). The torque transmission positioning seat 103 is connected to the engine main shaft 104 by a spline, and a locking nut is added for reinforcement to prevent loosening under high-speed operation. The starter generator stator assembly 201 is fastened to the housing by bolts, and a sealing ring is added at the connection to improve dustproof and waterproof performance.

[0130] 3. Main generator 4: The power specification is 1400kW. The main generator housing 401 is made of stainless steel with a thickness of 15mm. It has a dual cooling structure with built-in water cooling channel and air cooling channel. The water cooling channel is connected to the external cooling system, and the air cooling channel is connected to the main generator cooling channel 406 to achieve synergistic heat dissipation. The main generator heat dissipation fins 407 are designed with a high density array, with a height of 25mm, a thickness of 4mm, and a spacing of 8mm. Combined with forced air cooling, it greatly improves heat dissipation efficiency.

[0131] 4. Positioning and Lubrication Design: The axial clearance 409 of the main generator rotor assembly 405 is set to 1.0mm to accommodate the large thermal expansion of high-power motors; the bearing 404 is a self-aligning roller bearing (model 23224) with strong load-bearing capacity, and adopts a circulating lubricating oil method. The lubricating oil system is equipped with a cooler to ensure that the lubricating oil temperature is controlled below 50℃; the airflow hole 411 has 6 through holes with a diameter of 8mm, which are connected to the main shaft keyway gap and the auxiliary interface of the water cooling channel to form a composite airflow channel, which has the functions of pressure balance, auxiliary cooling and sealing.

[0132] 5. Isolation fence 3: Made of 10mm thick composite non-magnetic material (outer layer stainless steel + inner layer ceramic insulation layer), weighing 2.2kg, with a magnetic field isolation efficiency of up to 99%, and also has good heat insulation and sound insulation performance, reducing generator operating noise and heat transfer.

[0133] III. Work Process and Results

[0134] During startup, generator 2 drives the main shaft 104 of the engine to a speed of 2500 r / min, disengaging it and switching to power generation mode. During power generation, the free turbine output shaft 101 operates stably at 18000 r / min, and the total output power of the main generator 4 and generator 2 can reach 1500 kW, which can meet the needs of high-power emergency power generation. The dual cooling system works synergistically to keep the main generator's operating temperature below 80℃, maintaining stable output even after 8 hours of continuous operation in a high-temperature, dusty environment of 40℃. This embodiment exhibits excellent sealing performance, reliable torque transmission, and is suitable for long-term operation in harsh environments, extending its service life by 40% compared to traditional structures.

[0135] The examples provided in this invention are not intended to limit the implementation. Those skilled in the art will recognize that various variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations, and any obvious variations or modifications derived therefrom are still within the scope of this invention.

Claims

1. A turbine-powered generator structure with initiation function, characterized in that, It includes a dual-rotor turboshaft engine (1), a starter generator (2), an isolation fence (3), and a main generator (4); The starter generator (2) and the main generator (4) are both integrated on the intake side of the dual rotor turbine shaft engine (1) and are respectively connected to the corresponding output shaft of the dual rotor turbine shaft engine (1) in a direct connection without a reducer; the isolation fence (3) is connected between the starter generator (2) and the main generator (4) to isolate the magnetic field interference between the two.

2. The turbine generator power structure with initiation function according to claim 1, characterized in that, The magnetic circuit structure of the generator (2) and the main generator (4) is selected independently of each other, and includes at least any of the following combinations: the generator (2) adopts an axial flux motor and the main generator (4) adopts a radial flux motor with an inner rotor and an outer stator, or the generator (2) adopts an axial flux motor and the main generator (4) adopts a radial flux motor with an outer rotor and an inner stator, or both the generator (2) and the main generator (4) adopt axial flux motors, or both the generator (2) and the main generator (4) adopt radial flux motors.

3. The turbine generator power structure with initiation function according to claim 1, characterized in that, The dual-rotor turboshaft engine (1) includes: a free turbine output shaft (101), a main shaft locking nut (102), an engine main shaft (104), a core engine rotor (105), and a free turbine rotor (106). The free turbine output shaft (101) and the engine main shaft (104) are arranged in a concentric sleeve, and the free turbine output shaft (101) is connected to the free turbine rotor (106); The engine main shaft (104) is connected to the core engine rotor (105), and the core engine rotor (105) is connected to the free turbine rotor (106) via a pneumatic means.

4. The turbine generator power structure with initiation function according to claim 3, characterized in that, The generator (2) includes a generator stator assembly (201) and a generator rotor assembly (202), the generator rotor assembly (202) being connected to the engine main shaft (104) for transmitting torque and achieving axial positioning.

5. A turbine generator power structure with initiation function according to claim 4, characterized in that, The generator rotor assembly (202) is connected to the engine main shaft (104) via a torque transmission positioning seat (103); The torque transmission positioning seat (103) is connected to the engine main shaft (104) via a spline to transmit torque and achieves axial positioning via a shoulder.

6. A turbine generator power structure with initiation function according to claim 3, characterized in that, The main generator (4) includes: main generator housing (401), main generator stator assembly (402), main generator main shaft (403), bearing (404), and main generator rotor assembly (405). The main generator stator assembly (402) is fixedly installed inside the main generator housing (401); The main generator main shaft (403) is rotatably supported on the main generator housing (401) by bearings (404), and the main generator main shaft (403) is connected to the free turbine output shaft (101) by splines; The main generator rotor assembly (405) is coaxially arranged and connected to the main generator main shaft (403), rotates together with the main generator main shaft (403), and maintains a working air gap with the main generator stator assembly (402).

7. A turbine generator power structure with initiation function according to claim 6, characterized in that, The main generator housing (401) is provided with a main generator cooling channel (406) for introducing cold air from the intake side to cool the main generator.

8. A turbine generator power structure with initiation function according to claim 7, characterized in that, The outer periphery of the main generator housing (401) is provided with main generator heat dissipation fins (407).

9. A turbine generator power structure with initiation function according to claim 6, characterized in that, The main generator rotor assembly (405) is provided with a first positioning shoulder (408) and a second positioning shoulder (410) at both axial ends for axial positioning. A preset axial movement clearance (409) is provided at the second positioning shoulder (410).

10. A turbine generator power structure with initiation function according to claim 9, characterized in that, An airflow hole (411) is provided at one end of the main generator rotor assembly (405) near the first positioning shoulder (408). The airflow hole (411) is connected to the keyway gap of the main generator main shaft (403) to form an airflow channel.

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