Electric machine for integration into a 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

[0001] This application is a divisional application of the invention patent application filed on January 28, 2022, with application number 202210107172.3 and invention title "Electric Motor for Integration into Propulsion Engine". Technical Field

[0002] This manual generally pertains to electric motors used in conjunction with gas turbine engines. Background Technology

[0003] 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

[0004] 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.

[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 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.

[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. 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.

[0007] 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.

[0008] 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.

[0009] 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.

[0010] 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

[0011] 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:

[0012] Figure 1 One or more embodiments according to the present document are described. Figure 1 The cross-sectional view of the propulsion engine depicted above its central axis AA;

[0013] 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;

[0014] 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;

[0015] 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

[0016] Figure 5 Schematic depiction of one or more embodiments of the invention that can be incorporated into Figure 1 The diagram depicts a cross-sectional view of the electric motor in a propulsion engine. Detailed Implementation

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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) are 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.).

[0021] refer to Figure 1 The diagram schematically depicts a propulsion engine. Depending on the implementation, the propulsion engine can take various forms. In the embodiment described herein, the propulsion engine is a high-bypass turbofan engine. However, other types of turbofan engines are contemplated and are within the scope of this disclosure. Figure 1 As shown, the propulsion engine includes a motor disposed in the rear portion of the propulsion engine. The rear portion is axially positioned downstream of the core portion of the propulsion engine (e.g., in a direction parallel to the central axis of the propulsion engine). In embodiments, the motor converts the mechanical energy generated by the propulsion engine (e.g., generated from exhaust gas produced in the core portion) into electrical energy, which can be used to power the electrical system of the propulsion engine or components located elsewhere on the aircraft (including components containing the propulsion engine). As described herein, positioning the motor in the rear portion of the propulsion engine advantageously facilitates maintenance, repair, and replacement of the motor when the propulsion engine is mounted on the aircraft (e.g., on the wing or fuselage of the aircraft). The motor is designed to be integrated into the propulsion engine via a set of connections that can be removed without intrusive disassembly of the entire propulsion engine (e.g., without detaching the propulsion engine from the aircraft).

[0022] In one embodiment, the motor may be attached to the inner hub of the rear frame of the propulsion engine's turbine. An exemplary embodiment of the motor's structure is described in more detail herein. Still referring to... Figure 1 It should be understood that the depicted arrangement of the propulsion engine is merely exemplary and not limiting. For example, in an alternative embodiment, the motor may be axially positioned in front of the core portion.

[0023] Positioning the motor at the rear provides accessibility but introduces additional design considerations for the propulsion engine. The exhaust gas generated via the core section is at relatively high temperatures (e.g., exceeding approximately 700°C or higher in various embodiments), making motor cooling beneficial. Furthermore, the rear of the propulsion engine may not be directly connected to the aircraft incorporating it. Therefore, electrical signals directed to and from the motor are directed through the propulsion engine. In embodiments, for example, the propulsion engine includes an electrical system ( Figure 1 (Not depicted in the text), the electrical system includes connecting the motor 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 (e.g., from a bypass section extending radially outward from the core portion). In another embodiment, the wires are disposed outside the cooling conduit.

[0024] In embodiments, the motor control unit converts the electrical signals generated by the motor (between AC and DC signals, or vice versa) to provide to the propulsion engine or additional components incorporated into the aircraft. In embodiments, as described in more detail herein, the motor control unit may also provide control signals to the motor 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 and the additional components of the propulsion engine. In embodiments, the motor control unit may be located within the propulsion engine at a location removed from the motor (e.g., axially forward of the core section), or elsewhere on the aircraft (e.g., in a pylon).

[0025] Still referencing Figure 1The propulsion engine includes a fan, a low-pressure compressor, a high-pressure compressor, and a combustor. The combustor mixes air compressed by the high-pressure compressor with fuel to produce combustion gases. These combustion gases flow downstream through a high-pressure turbine and a low-pressure turbine to produce pressurized exhaust gases. A first shaft connects the high-pressure compressor to the high-pressure turbine. A second shaft connects the low-pressure turbine to the fan and the low-pressure compressor. In an embodiment, the high-pressure compressor, combustor, and high-pressure turbine may collectively form a core section. The core section can produce combustion gases, which are directed to the low-pressure turbine and then power the fan via the second shaft. The low-pressure turbine may include multiple rows of blades that rotate in response to the combustion gases from the core section, thereby rotating the second shaft and powering the fan, low-pressure compressor, and motor.

[0026] The turbine rear frame is positioned behind the low-pressure turbine (e.g., offset from the low-pressure turbine in a rearward direction (e.g., axial direction) extending parallel to the central axis). The turbine rear frame includes a plurality of struts extending between the inner hub and the outer housing. The turbine rear frame provides an exhaust flow path for exhaust gas exiting from the low-pressure turbine. The inner hub and outer housing may be circumferentially surrounding a second shaft, and the plurality of struts may be distributed around the second shaft. In embodiments, the plurality of struts serve as outlet guide vanes to straighten the exhaust gas flow, which may flow over the tail cone to improve the performance of the propulsion engine. It should be understood that the turbine rear frame may include any number of struts in any arrangement consistent with this disclosure.

[0027] Still referencing Figure 1 The propulsion engine includes a core cowling and a rear skin. The core cowling defines the flow path of air compressed by the fan. In one embodiment, the rear skin is bolted (not depicted) to a housing of the turbine rear frame. In another embodiment, exhaust gas exits the propulsion engine via an outlet defined by the turbine rear frame, the rear skin, and the tail cone.

[0028] Now for reference Figure 2 It shows that in Figure 1 A detailed view of a cross-sectional portion of the motor, depicted within the dashed line boundary. In the depicted embodiment, the motor includes a stator assembly and a rotor assembly. The stator assembly is directly connected to the propulsion engine via a first engine stator component and a second engine stator component. The first and second engine stator components may vary depending on the specific location of the motor within the propulsion engine. For example, as described herein... Figure 1 As described, the electric motor is located at the rear of the propulsion engine. In such an embodiment, the first engine stator component can be a flow-limiting structure, such as... Figure 1The turbine rear frame depicted (e.g., a stator assembly may be attached to the inner hub), and the second engine stator component may be another component (e.g., a turbine component, such as a bearing support structure, etc.) extending radially between the second shaft and the inner hub. Alternative locations for the motor are contemplated and are within the scope of this disclosure. For example, in an embodiment, the motor is disposed between the end of the second shaft (e.g., axially forward of the rear end of the second shaft and the turbine rear frame). In such an embodiment, the first engine stator component may be another flow path defining structure (e.g., an intermediate turbine frame, etc.). Various connection points between the motor and the propulsion engine are contemplated and are within the scope of this disclosure.

[0029] The stator assembly includes a stator, and the rotor assembly includes a rotor. In the depicted embodiment, the rotor assembly is disposed radially inside the stator assembly (e.g., the entire rotor assembly is disposed closer to the second shaft than the stator assembly). In the embodiment, the stator assembly circumferentially surrounds the rotor assembly such that the rotor assembly is radially disposed between the stator assembly and the second shaft of the propulsion engine. In the embodiment, the motor operates as a generator to convert the rotational energy of the second shaft (e.g., during flight operation of the propulsion engine) into electrical energy that can be transmitted to other components of the aircraft. In the embodiment, the motor operates as an electric motor to provide torque to the second shaft (e.g., to improve the operating efficiency of the propulsion engine).

[0030] The internal rotor configuration of an electric motor is advantageous for its compactness (e.g., aerodynamic performance) and operability. For example, during motor operation, the internal rotor configuration can promote long-term operability in embodiments where the stator assembly is located radially inward of the rotor assembly by reducing the rotational load applied to the structural components supporting the rotor. Furthermore, Figure 2 The internal rotor configuration of the electric motor depicted herein helps the stator assembly act as a shield to prevent damaged rotor components from traveling radially outward and affecting additional components of the propulsion engine. For example, if the motor fails, a portion of the rotor assembly may break off and disconnect from the second shaft. If left unobstructed, such a damaged component could interfere with the operation of the propulsion engine. However, due to the internal rotor configuration of the motor, such a damaged rotor component is contained within a rotor cavity defined by the stator assembly. The stator assembly's containment of debris reduces the likelihood that a motor failure will affect the operation of other components of the propulsion engine or high-energy components released from the propulsion engine. Embodiments with an external 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.

[0031] exist Figure 2In the illustrated embodiment, the motor is directly connected to the second shaft via a rotor support structure of the rotor assembly. In this embodiment, the rotor support structure includes attachment elements (e.g., grooves, protrusions, etc., not shown) that slidably engage with corresponding attachment elements on the second shaft. For example, in this embodiment, the rotor support structure may slidably engage with the second shaft at its rear end. A locking nut (not depicted) secures the rotor support structure to the second shaft, allowing the rotor assembly to rotate together with the second shaft to facilitate the generation of electricity via the rotation of the second shaft.

[0032] This embodiment, in which the rotor assembly is directly attached to the second shaft, may be referred to herein as an "embedded generator embodiment." In the embedded generator embodiment, the rotor assembly may be at least partially supported by a bearing assembly supporting the second shaft (e.g., an engine bearing assembly—not depicted—supporting the rear of the propulsion engine, axially positioned near the turbine rear frame). The embedded generator embodiment can be advantageous because the motor can serve as a damper for the shaft's natural frequency. In the embodiment, components of the rotor assembly (e.g., rotor support structures) may be structurally designed to modify the natural frequency of the second shaft (e.g., altering the natural vibration frequency of the second shaft compared to embodiments without a motor). For example, in the embodiment, the stiffness and volume of the rotor support structure can be selected to remove the natural vibration frequency of the second shaft from the range of vibration modes that the vibration of the second shaft might excite in other components of the propulsion engine, thereby avoiding structural integrity problems associated with high-amplitude oscillations.

[0033] In one embodiment, the motor may be designed to variably influence the natural vibration frequency of the second shaft via external control. In the depicted embodiment, for example, the motor may be communicatively coupled (e.g., via the wires and 342 described herein and the electrical connection device) to a motor control unit. The motor control unit can control the motor by changing the electrical load based on power demand. In one embodiment, the motor control unit is located at a different axial position from the motor within the propulsion engine. In another embodiment, the motor control unit is located at the same axial position as the motor 100 within the propulsion engine.

[0034] In one embodiment, for example, the motor control unit receives instructions from another component associated with the aircraft (e.g., the engine power control unit) to adjust the motor load to change the rotational energy extracted from the second shaft via the rotation of the rotor, thereby controllably suppressing vibrations of the second shaft. For example, the motor control unit may change the electrical load of the motor in response to detected vibrations of the second shaft (e.g., by disconnecting and connecting electrical connections between its coils) to suppress the detected vibrations. This electrical load control of the motor control unit can occur in both generator operating mode and motor operating mode of the motor.

[0035] Still referencing Figure 2The rotor assembly also includes a rotor attachment arm extending axially forward from the end of the rotor support structure. The rotor attachment arm holds the rotor in a relationship spaced apart from the stator and the second shaft. In an embodiment, the rotor includes a plurality of permanent magnets circumferentially distributed around the stator, such that rotation of the rotor about the stator generates an electrical signal. It should be understood that alternative rotor configurations are contemplated depending on the implementation of the motor. For example, in an embodiment, the rotor may include a plurality of electromagnets and active circuitry. Various implementations are contemplated in which the motor is configured as an induction generator, a switched reluctance generator, an asynchronous AC motor, or any suitable type of generator.

[0036] In one embodiment, the stator assembly circumferentially surrounds the rotor assembly. In another embodiment, the stator assembly (e.g., the stator support assembly described herein) includes multiple circumferential segments, each of which can be individually detached from the propulsion engine 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 (e.g., at an end remote from the second shaft), as access to the motor for maintenance or replacement may be more time-consuming in such embodiments.

[0037] In the depicted embodiment, the stator assembly is attached to a first engine stator component and a second engine stator component via a first connecting bolt and a second connecting bolt, respectively. The stator assembly includes a stator support assembly that holds the stator in a desired position relative to the rotor. The stator support assembly includes a stator support arm. The stator support arm extends in an axial direction (e.g., parallel to a second axis) and defines a stator support surface, wherein the stator is attached to the stator support assembly.

[0038] In one embodiment, the stator support arm extends axially over the entire rotor to define a rotor cavity extending between the stator support arm and the second shaft. In another embodiment, the axial length of the stator support arm is greater than the length of the rotor. Besides providing structural support for the stator, the stator support arm also helps to accommodate any fragments associated with the rotor assembly (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. That is, the stator support arm can serve as a shield to prevent a failure of the rotor assembly from interfering with the operation of other components of the propulsion engine, or to prevent the rotor assembly from launching high-energy fragments outside the propulsion engine. In another embodiment, the stator support arm is the sole receiving mechanism for the propulsion engine to accommodate such fragments from the rotor assembly. That is, the inner rotor configuration of the motor eliminates the need for a fragment shield surrounding the motor.

[0039] In one embodiment, the stator support arm includes a substantially cylindrical structure surrounding a second axis. In another embodiment, the substantially cylindrical structure is a monolithic continuum. In yet another embodiment, the stator support arm includes a plurality of circumferential segments, each of which is connected to each other to facilitate the individual removal of each circumferential segment radially away from the second axis. 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 may include gaps around its circumference.

[0040] In this embodiment, the structure of the stator support assembly facilitates both electrical and fluid connections of the motor. For example, in Figure 2 In the illustrated embodiment, the motor includes a connector support extending radially between the first engine stator component and the stator support arm. In this embodiment, the connector support includes at least one opening for supporting an electrical connection device. It should be understood that embodiments are also conceivable in which the motor does not include the connector support, or the connector support is disposed with... Figure 2 The locations shown are different. The electrical connection device can conductively connect wires from the stator to external wires. In an embodiment, the connector support acts as a retainer for the electrical connection device to facilitate electrical connection of the motor to other components of the propulsion engine. In an embodiment, the connector support includes a plurality of openings circumferentially distributed around the stator support assembly. The electrical connector can extend through each of the plurality of openings to facilitate the supply of electrical signals generated by the motor to external components. It should be understood that alternative locations are contemplated for the electrical connection device. That is, the electrical connection device can be positioned along the wires and 342 in relation to... Figure 2 Alternative locations depicted in the diagram may differ (e.g., axially forward of the motor). In such embodiments with alternative positioning for electrical connections, the motor may not include a connector support.

[0041] In one embodiment, the motor includes a cooling system that distributes coolant to various parts of the motor. In the depicted embodiment, the cooling system includes an inlet manifold and a stator manifold. The inlet manifold receives coolant air from a portion of the propulsion engine outside the motor. In one embodiment, the inlet manifold is part of or connected to another cooling duct of the propulsion engine. In one embodiment, the inlet manifold may be directed through a first engine stator component (e.g., via...). Figure 1 (One of the struts of the turbine rear frame depicted). The stator manifold supplies coolant to the stator 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. For example, in the depicted embodiment, wires 342 extend through the stator manifold and inlet manifold 356, respectively, and are conductively connected within the stator manifold via electrical connections. Embodiments in which the wires are disposed outside the cooling system are also contemplated. In embodiments, the stator support arm includes holes or openings to access different... Figure 2 The cooling manifolds depicted in the text.

[0042] exist Figure 2 In the illustrated embodiment, electrical and fluid connections via the cooling system are located at the rear end of the stator (e.g., via a connection portion of the stator manifold). It should be understood that alternative embodiments are contemplated and are within the scope of this disclosure. For example, in embodiments, wires may extend from the axial front end of the stator, and the stator manifold may extend through a stator support arm to facilitate attachment and connection to the axial front end of the stator (e.g., the stator manifold may not include a connection portion including a bend, as in the depicted embodiment). In such embodiments, electrical connection devices may also be located axially forward of the stator. For example, electrical connection devices may be supported within or outside a portion of the stator manifold extending through the stator support arm to facilitate electrical connection to external wires. Such embodiments may not include connector supports (the depicted embodiment may also not include connector supports). Various combinations of electrical and fluid connection structures are contemplated and are within the scope of this disclosure.

[0043] In one embodiment, the motor includes a heat shield. In another embodiment, the heat shield is not directly attached to the second shaft, but rather circumferentially surrounds the rear end of the second shaft, the stator assembly, and the rotor assembly. In yet another embodiment, the heat shield is attached to a first engine stator assembly. For example, in one embodiment, the heat shield is attached to a connecting flange of the first engine stator assembly via a first connecting bolt. In another embodiment, the heat shield includes at least two components. In another embodiment, for example, the heat shield includes a stator portion circumferentially surrounding the stator assembly and a rotor portion extending axially rearward of the rotor. In yet another embodiment, individual portions of the heat shield can be individually removed from the propulsion engine to facilitate access to the rotor assembly without disrupting the stator assembly connections.

[0044] Figure 2 The view depicted corresponds to a single circumferential section of the motor. Therefore, it should be understood that the motor may include any number of circumferentially distributed sections around the second axis. 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., a stator support arm) that can be divided into multiple segments extending in the axial direction and extending to each other. In an embodiment, the motor includes segments similar to those distributed around its circumference. Figure 2 The cooling system depicted includes multiple cooling systems (e.g., having multiple manifolds, electrical connectors, and wires extending through them). Furthermore, components of the motor (e.g., stator support assemblies, thermal shields, etc.) can be connected to the propulsion engine at any number of points along the circumference of the propulsion engine. That is, the motor may include multiple first and second connecting bolts distributed around its circumference.

[0045] The various components of the electric motor and propulsion engine have been described; 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 fully accessible, the tail cone can be removed. After removing the tail cone, at least a portion of the motor can be removed from the propulsion engine. Depending on the type of operation being performed and the process followed, all or part of the motor can be removed. For example, in one embodiment, a plurality of first and second connecting bolts attaching the stator assembly to the first and second engine stator components can be removed to facilitate the removal of the heat shield. The connection between the rotor support structure and the second shaft can then be loosened, thereby facilitating the removal of the rotor assembly for replacement and / or maintenance. The stator assembly can also be removed from the first and second engine stator components.

[0046] In this embodiment, instead of removing the stator assembly, the rotor assembly can be removed from the second shaft without removing the connections at the multiple first and second connecting bolts. The non-radial overlap structure of the stator and rotor assemblies facilitates access to and removal of the rotor assembly from the propulsion engine without damaging the stator assembly, and promotes rapid and efficient maintenance operations.

[0047] The way the electric motor is positioned and connected within the propulsion engine thus facilitates the access and removal of the motor without removing the propulsion engine's mounting position in front of the turbine's rear frame (e.g., Figure 2 Any component located in the opposite direction of the axial direction depicted in the diagram, or radially inward. When the propulsion engine is mounted on the wing or fuselage of an aircraft, this non-invasive access to the motor facilitates the maintenance or replacement of the various components of the motor, minimizing the time during which the aircraft may be inoperable if the motor requires maintenance. Furthermore, the manner in which the motor is connected to the various components of the propulsion engine provides a streamlined process for removing the motor from the propulsion engine.

[0048] 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. The motor 400 may include components described herein. Figure 2 The components of the motor are described. Therefore, in Figure 3 The same reference numerals are used to indicate the assembly of such identical components. Motor 400 is also an embodiment of an embedded generator, including a rotor fixedly attached to a second shaft. Motor 400 includes, regarding Figure 2 The stator assembly of the motor described herein. Motor 400 also includes a rotor assembly 402, which is structurally similar to the one described above. Figure 3The described rotor assembly differs in that rotor assembly 402 includes a rotor support structure 404 that extends axially forward from the point where it is attached to the second shaft. In an embodiment, the rotor support structure 404 is connected to the second shaft at its rear end (e.g., by engaging a feature on the second shaft). Figure 3 As shown, the rotor support structure 404 extends axially forward, and the rotor attachment arm 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 integrated into the motor 400 and the propulsion engine. In an embodiment, the rotor support structure 404 extends only in the radial direction.

[0049] 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. The motor 500 may include components described herein. Figure 2 The components of the motor are described. Therefore, in Figure 4 The same reference numerals are used to indicate the assembly of such identical components. The motor 500 differs from the motor in that it is not directly connected to the second shaft, but rather indirectly connected via a motor shaft. The motor shaft is attached to the rear end of the second shaft via an intermediate shaft member. In embodiments, the intermediate shaft member is attached to the second shaft such that axial and radial vibrations of the second shaft are not transmitted to the motor shaft. For example, in an embodiment, the intermediate shaft member includes a sleeve shaft with a first spline (not shown) at its front end. The first spline can be inserted into an opening at the rear end of the second shaft to rotatably connect the second shaft and the motor shaft. A second spline (not depicted) at the rear end 507 of the intermediate shaft member can be inserted into a connecting end of the motor shaft. This splined connection between the motor shaft and the second shaft allows axial and radial movement of the motor shaft relative to the second shaft such that the motor 500 does not alter the natural vibration frequency of the second shaft. In embodiments, the intermediate shaft member may include a bellows spring member instead of a sleeve shaft to allow relative axial and radial movement of the motor shaft relative to the second shaft. In one embodiment, the intermediate shaft member includes a shear section configured to separate (e.g., break) when subjected to a predetermined shear load. In another embodiment, the intermediate shaft member and the motor shaft may be integrated into a single component.

[0050] The motor shaft is radially supported by a generator bearing assembly, which is bolted to a second engine stator component. The generator bearing assembly includes a bearing support frame extending radially between the motor shaft and the second engine stator component. As depicted, the bearing support frame includes an axial portion that, together with the motor shaft, defines a bearing cavity. A first bearing support arm and a second bearing support arm extend axially from the bearing support frame. A first generator bearing extends between the first bearing support arm and a first portion of the motor shaft, and a second generator bearing extends between the second bearing support arm and a second portion of the motor shaft to rotatably contact the motor shaft (e.g., an inner ring connected to the motor shaft may accommodate the first and second generator bearings to provide this rotatable contact). Depending on the implementation, the first and second generator bearings may comprise various types of bearings (e.g., ball bearings, roller bearings, etc.). The first and second generator bearings protect the motor from radial and axial movement of the second shaft.

[0051] Figure 4 An engine bearing assembly associated with a propulsion engine is also depicted. For example, in one embodiment, the engine bearing assembly may support a second shaft via a second engine stator component (e.g., the second engine stator component may include a support structure extending radially inward from the inner hub of the turbine rear frame). The engine bearing assembly includes an engine bearing support arm extending from the second engine stator component. The engine bearing support arm, together with the second shaft, defines an engine bearing cavity. The engine bearing is disposed within the engine bearing cavity and extends between the engine bearing support arm and the second shaft. The engine bearing rotatably contacts the second shaft such that the second engine stator component supports the second shaft.

[0052] Therefore, the motor 500 is supported by dedicated bearings (e.g., first generator bearing and second generator bearing) on ​​the motor shaft to protect the motor from vibrations of the second shaft. In an embodiment, the engine bearing cavities and bearing housings are fluidly isolated from each other to mitigate the risk of contamination of the engine bearing assemblies during maintenance of the motor 500. For example, in Figure 4 In the illustrated embodiment, the generator bearing assembly includes a first sealing member extending between a first bearing support arm and a motor shaft, and a second sealing member extending between a second bearing support arm and a motor shaft. The first and second sealing members may be constructed of a suitable compliant material (e.g., a labyrinth air seal) to create a seal at the interface between the first and second sealing members and the motor shaft.

[0053] The engine bearing assembly also includes a sealing member disposed between the engine bearing support arm and the second shaft. The sealing member creates a seal at its interface with the second shaft. The sealing member is axially disposed between the engine bearing and the generator bearing assembly, thereby fluidly isolating the engine bearing assembly from the generator bearing assembly. 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 includes an engine bearing lubrication system and a generator bearing lubrication system. The generator bearing lubrication system includes an oil supply line supported by a bearing support frame. In this embodiment, the oil supply line extends into the bearing cavity through an opening in an axial portion. The generator bearing lubrication system also includes an oil injector with an outlet located near the first and second generator bearings, such that during operation of the first and second generator bearings, oil from a lubricant source (not shown) passes through the oil supply line and is sprayed onto the surfaces of the first and second generator bearings to provide lubrication and cooling. The generator bearing lubrication system also includes an oil removal device that facilitates oil circulation out of the bearing cavity.

[0054] The engine bearing lubrication system includes an oil supply line 548 and an injector 550, the injector 550 including an outlet near the engine bearing assembly to provide lubrication during engine bearing operation. Lubricant is supplied to both the generator bearing assembly and the engine bearing assembly using a separate bearing lubrication system (e.g., a separate oil supply line and 548). Figure 4 The embodiments depicted mitigate the risks associated with maintaining the motor 500.

[0055] While the depicted embodiments combine an oil-based generator bearing lubrication system and an engine bearing lubrication system, it should be understood that alternative lubrication systems using different types of lubricants are contemplated and are within the scope of this disclosure. According to this disclosure, various types of fluid-based lubricants (e.g., synthetic polymer-based lubricants), gas-based lubricants, or solid lubricants may also be used. Isolating separate lubrication systems associated with the generator and engine bearings generally avoids complications in the engine bearing assembly caused by maintenance of the motor 500, thereby preventing interference with the operation of the rest of the propulsion engine.

[0056] Still referencing Figure 4 Motor 500 and the motor mentioned in this article Figure 2The motor described also differs in that it includes a rotor assembly 506, which is structurally different from the rotor assembly described herein. The rotor assembly 506 includes a rotor support structure 508 attached to the motor shaft via a mounting flange. The rotor support structure 508 is attached to the mounting flange by connecting bolts extending from the mounting flange and the rotor support structure 508. The rotor support structure 508 extends from the motor shaft, and rotor attachment arms extend axially therefrom to support the rotor in a desired position. In an embodiment, the rotor support structure 508 extends diagonally from the motor shaft (e.g., similar to those described herein). Figure 2 and Figure 3 The rotor support structure described is 404.

[0057] In the depicted embodiment, the rotor is positioned radially inside the stator assembly. As discussed herein, this inner rotor design facilitates the independent removal of the rotor assembly 506. Because the mounting flange of the motor shaft is located axially rearward of the bearing support frame, the connecting bolts can be accessed without removing the bearing support frame, allowing the rotor assembly 506 to be removed independently of the stator assembly. Furthermore, due to the inner rotor configuration of the motor 500, the stator support arm 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, intermediate shaft assembly, generator bearing assembly) are also contemplated, wherein the rotor is positioned radially outside the stator assembly.

[0058] The separate shaft connection of the motor 500 via the motor shaft further facilitates the separation of the motor 500 from the propulsion engine by separating the intermediate shaft assembly. For example... Figure 4 As shown, the propulsion engine includes a separation device extending from the second engine stator component. The separation device axially overlaps with the intermediate shaft component, such that when the separation device is activated, it performs an action on the intermediate shaft component to separate the motor shaft from the second shaft, thereby protecting the second shaft from the effects of a motor 500 failure through mechanical disconnection of the motor 500 from the second shaft.

[0059] To facilitate the removal of motor 500 from the propulsion engine via the splines of the intermediate shaft component, and in accordance with the provisions of this article... Figure 3 Compared to the described generator assembly, the way the stator assembly is connected to the propulsion engine can be modified. For example... Figure 4As shown, the stator assembly is not directly connected to the second engine stator component, but rather to a bearing support frame. The bearing support frame is connected to the second engine stator component via a first connecting bolt 552, and the stator support arm is connected to the bearing support frame via a second connecting bolt 554. An axial portion 556 of the bearing support frame extends between the first connecting bolt 552 and the second connecting bolt 554 to axially separate the stator support arm from the second engine stator component. In an embodiment, the first connecting bolt 552 can be removed to facilitate removal of the motor shaft from the intermediate shaft assembly 502 via a spline connection. Therefore, the spline connection provided by the intermediate shaft assembly facilitates the removal of the entire motor 504 (e.g., motor shaft, bearing support frame, generator bearing assembly, rotor assembly 506, and stator assembly) as a single module, reducing the risk of contamination. The intermediate shaft assembly 502 can also be removed after the motor 500 has been removed.

[0060] In one embodiment, the second connecting bolt 554 can be loosened to facilitate the removal of the stator assembly without the use of a separation device (e.g., removing connecting bolts 327, 554, and 512 can facilitate the removal of the rotor assembly 506 and the stator assembly from the propulsion engine independently of the bearing support frame). Therefore, the depicted design promotes flexibility in operations that can be performed to remove the motor 500 (or portions thereof) from the propulsion engine. In one embodiment, the bearing support frame and the stator support arm can be constructed from different materials to achieve the desired functionality and durability. In another embodiment, the stator support arm and the bearing support frame are integrated as a single part.

[0061] 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. The motor 600 may include components described herein. 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 defined at least partially by a bearing support frame and a second engine stator component. Figure 5 As shown, the generator bearing assembly 602 includes, regarding Figure 4 The first and second generator bearings are described, but only include a single generator bearing seal member 622 axially disposed behind the second generator bearing. The engine bearing assembly 604 includes, regarding... Figure 4The described engine bearing includes, but is further described, a single engine bearing seal member 606 axially positioned in front of the engine bearing. Seals 622 and 606 seal a common reservoir to contain lubricant supplied to the bearing.

[0062] In motor 600, the common reservoir is not axially sealed between the first and second generator bearings and the engine bearing. That is, regarding... Figure 4 The described bearing cavities 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 and second generator bearings, as well as the engine bearing. For example, in the depicted embodiment, a bearing lubrication system is used to supply lubricant to the engine bearing, as well as the first and second generator bearings. The bearing lubrication system includes an oil supply line 610 extending from a lubricant source (not shown) into a coolant cavity. The oil supply line 610 branches into a generator section extending axially rearward into the bearing cavity and an engine section extending axially forward into the bearing cavity 541. An oil nozzle at the end of the generator section includes an outlet for supplying oil to the first and second generator bearings. An oil nozzle 620 located at the end of the engine section includes an outlet for supplying oil to the engine bearing. The bearing lubrication system also includes one or more discharge channels located near each of the bearings 524 and 542 for receiving oil after it has been applied to the bearings 524 and 542. Embodiments may incorporate the discharge channels in a portion of the second engine stator assembly located near the separation device. Discharge channels 628 and 630 allow oil near bearings 524 and 542 to be discharged into a common storage tank. A cleaning device directs the oil to a cleaning line for filtration and reuse.

[0063] Therefore, the common reservoir of motor 600 facilitates the use of a single bearing lubrication system (e.g., including a single oil supply line 610 from a lubrication source), and includes a ratio to that of... Figure 4 The described motor 500 has a simpler structure than the multiple lubrication systems associated with it (e.g., generator bearing lubrication system and engine bearing lubrication system). (Regarding...) Figure 4 Compared 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.

[0064] 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.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] 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.

[0069] Further aspects of the invention are provided by the subject matter in the following clauses:

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 6. The motor according to any of the preceding clauses, wherein the rotor assembly is directly connected to the end of the shaft.

[0076] 7. The motor according to any of the foregoing clauses, wherein no part of the stator assembly extends axially behind the rotor assembly.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] 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.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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.

[0097] 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.

[0098] 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.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] 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.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 37. The propulsion engine according to any of the preceding clauses, wherein the intermediate shaft member and the motor shaft are integrated components.

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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 of the various embodiments described herein, provided that such modifications and variations fall within the scope of the appended claims and their equivalents.

Claims

1. An electric motor, characterized in that, include: Stator assembly, connected to an engine stator component of a propulsion engine, the stator assembly comprising: A stator support structure, which is fixedly attached to the engine stator component; Stator, the stator being disposed on the support surface of the stator support structure; and A motor shaft, which is connected to an end of the shaft of the propulsion engine via an intermediate shaft member, the 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 defining a bearing cavity together with the motor shaft; A first motor bearing and a second motor bearing, the first motor bearing and the second motor bearing extending radially from the bearing support frame to rotatably contact the motor shaft; A sealing member is axially disposed behind the motor bearing and extends from the bearing support frame to the motor shaft; A rotor support structure, the rotor support structure being 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.

2. The motor according to claim 1, characterized in that, The bearing cavity is defined by the bearing support frame and the motor shaft, and the engine bearing of the propulsion engine is disposed within the bearing cavity.

3. The motor according to claim 2, characterized in that, Further includes: An oil supply line extends 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, the first oil nozzle extending from the oil supply line and disposed near the motor bearing; and A second oil nozzle extends from the oil supply line and is positioned close to the engine bearing.

4. The motor according to claim 3, characterized in that, in: 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 into the common reservoir through the axial portion of the bearing support frame.

5. The motor according to claim 1, characterized in that, The engine stator component is a first engine stator component, and the motor further includes an engine bearing support arm connected to a second engine stator component. The engine bearing support arm, together with the shaft of the propulsion engine, defines an engine bearing cavity.

6. The motor according to claim 5, characterized in that, It further includes a first sealing member and a second sealing member, which extend between the bearing support frame and the motor shaft to seal the bearing cavity.

7. The motor according to claim 5, characterized in that, Further includes: The first oil supply line extends into the bearing cavity through the bearing support frame; as well as A second fuel supply line extends into the engine bearing cavity.

8. The motor according to claim 1, characterized in that, It 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.

9. The motor according to claim 1, characterized in that, The intermediate shaft member allows the motor shaft to move relative to the shaft of the propulsion engine in both the axial and radial directions.

10. The motor according to claim 9, characterized in that, The intermediate shaft includes a sleeve shaft, the sleeve shaft having a first spline at a first end and a second spline at a second end, wherein the first spline and the second spline are inserted into openings at the ends of the shaft and the motor shaft of the propulsion engine to allow movement of the motor shaft in the axial and radial directions.

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