3D-Printed Generator Rotor Cooling for Wet and Dry Cavities
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Solution Overview
Problem
Current starter/generator systems in aircraft engines face challenges in efficiently managing heat generated during operation, particularly in wet and dry cavity systems, which affect manufacturing processes and cooling system design.
Innovation Solution
The method involves using three-dimensional printing to manufacture a main rotor with a rotor shaft featuring closed and open outlets for liquid coolant conduits, allowing for both closed and open coolant pathways within the rotor core, enabling efficient heat management in starter/generator systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional machining or casting methods are used to manufacture the main rotor, then manufacturing processes are well-established and reliable, but the ability to integrate complex liquid coolant conduits and outlets efficiently is limited
Solution Approach 1:
The patent combines multiple functions (structural support, coolant flow paths, and outlet positioning) into a single integrated main rotor component manufactured by 3D printing. The liquid coolant conduits are embedded within the rotor core structure, merging the cooling system with the mechanical rotor assembly, thereby reducing the number of separate parts and assembly steps while maintaining manufacturing reliability
Solution Approach 2:
The 3D printing process enables the creation of complex three-dimensional coolant conduits and outlets that cannot be achieved with conventional machining or casting. The technology allows coolant pathways to be routed through the interior volume of the rotor core in sophisticated patterns, adding dimensional complexity to the cooling system design without increasing manufacturing difficulty
2Temperature
If a wet cavity system is used where the main rotor and main stator are exposed directly to liquid coolant, then heat dissipation is highly effective, but the system requires direct coolant exposure which increases system complexity and potential leakage points
Solution Approach 1:
The patent introduces an intermediary cooling approach where liquid coolant conduits are embedded within the rotor core structure, allowing coolant to flow through controlled internal passages rather than direct exposure. This intermediary system maintains effective heat dissipation while reducing the complexity associated with direct wet cavity cooling, including fewer external coolant distribution components and reduced leakage risks
3Device complexity
If a dry cavity system is used with liquid coolant directed through the cavity within liquid conduits, then system complexity is reduced, but heat dissipation effectiveness is compromised
Solution Approach 1:
The patent merges the advantages of both wet and dry cavity systems by embedding coolant conduits within the rotor core structure itself. This integration maintains the simplicity of a dry cavity system (coolant flows through defined conduits rather than direct exposure) while achieving the heat dissipation effectiveness of a wet system (coolant is in close thermal contact with the rotor core through the embedded conduits)
4Productivity
If three-dimensional printing is used to manufacture the main rotor, then complex coolant conduit integration is enabled and manufacturing efficiency is improved, but the process requires advanced additive manufacturing capabilities
Solution Approach 1:
The 3D printing process allows all coolant conduits, outlets, and structural features to be pre-integrated into the main rotor during the single manufacturing step. This preliminary action of creating the complete integrated structure in one build eliminates subsequent assembly operations for installing coolant systems, thereby improving manufacturing efficiency despite the advanced technology required
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the integration of liquid coolant conduits within the rotor core, enhancing heat dissipation and enabling the starter/generator systems to operate effectively in both wet and dry cavity configurations, improving manufacturing efficiency and system performance.
Implementation Method 1
printing at least part of a rotor shaft by a three-dimensional printing process
Implementation Method 2
A liquid cooling system may be provided to reduce the heat
Data Source
AI summary
A method for manufacturing a main rotor for a generator is provided. The method includes printing at least part of a rotor shaft by a three-dimensional printing process. The step of printing at least part of the rotor shaft includes printing a plurality of closed outlets and a plurality of open outlets. A rotor core is printed by the three-dimensional printing process. The step of printing the rotor core includes printing a plurality of liquid coolant conduits that extend through the rotor core and fluidly connecting the plurality of liquid coolant conduits to the plurality of closed openings.