Air cycle machine with separate compressor and turbine and fan and turbine
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Solution Overview
Problem
Air cycle machines face challenges with high temperature loads and material limitations, as existing systems rely on metal components which are heavy, costly, and prone to stress and deflection, especially when using non-metallic materials for critical components like the fan and turbines.
Innovation Solution
The air cycle machine design separates the fan and second turbine from the compressor and first turbine, using non-metallic materials for the fan rotor, second turbine, and shafts, while maintaining metal components for the compressor and first turbine, allowing for slower speeds and reduced temperature exposure, facilitating the use of additive manufacturing and injection molding to reduce weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal components are used for fan and turbines, then structural integrity and temperature resistance are improved, but weight and cost increase
Solution Approach 1:
The system is divided into two separate groups: metal components (compressor, first turbine) that handle high temperature loads, and non-metallic components (fan, second turbine) that operate at lower temperatures. This segmentation allows each component to use the most appropriate material for its specific operating conditions.
Solution Approach 2:
Different materials are selected based on the local temperature conditions of each component. The fan and second turbine use non-metallic materials because they operate in cooler zones, while the compressor and first turbine use metal materials where high temperature resistance is required.
2Weight of moving object
If non-metallic materials are used for fan and second turbine, then weight and cost are reduced, but temperature and stress resistance deteriorate
Solution Approach 1:
The system separates components based on their stress and temperature exposure. The fan and second turbine, which experience lower stresses and temperatures, use non-metallic materials to reduce weight. The compressor and first turbine, which experience higher stresses and temperatures, use metal materials to ensure reliability.
Solution Approach 2:
The design creates a hierarchical structure where the non-metallic fan and second turbine are supported by the metal compressor and first turbine, allowing the non-metallic components to function reliably in their lower-stress environment while benefiting from the overall system's robust metal framework.
3Device complexity
If fan and second turbine are integrated with compressor and first turbine, then device complexity is reduced, but material selection and manufacturing flexibility are limited
Solution Approach 1:
The system is organized into two functional groups that can be manufactured and assembled separately. The metal group (compressor, first turbine) and the non-metallic group (fan, second turbine) can be produced using different manufacturing processes and materials, then integrated into the final assembly, providing manufacturing flexibility without excessive complexity.
Solution Approach 2:
The metal components serve dual purposes: they perform their primary function while also providing structural support and housing for the non-metallic components. This multi-functionality reduces the need for additional supporting structures, simplifying the overall design.
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 configuration reduces stress and heat on the fan and turbine, improves dynamic performance, and allows for the use of lighter, less expensive non-metallic materials, while maintaining structural integrity and addressing high temperature challenges.
Implementation Method 1
Air downstream of the air cycle compressor is connected to be delivered across a first turbine. The air cycle compressor is driven by the first turbine through a shaft.
Implementation Method 2
Air downstream of the first turbine is connected to a second turbine. The second turbine is connected to deliver air downstream. The second turbine is connected with a second shaft to drive a fan rotor.
Implementation Method 3
The fan rotor is configured to deliver a source of air across a heat exchanger positioned between the inlet and the air cycle compressor.
Implementation Method 4
The fan rotor is configured to deliver a source of air across a heat exchanger positioned between the inlet and the air cycle compressor.
Data Source
AI summary
An air cycle machine includes an air inlet connected to an air cycle compressor. Air downstream of the air cycle compressor is connected to be delivered across a first turbine. The air cycle compressor is driven by the first turbine through a shaft. Air downstream of the first turbine is connected to a second turbine. The second turbine is connected to deliver air downstream. The second turbine is connected with a second shaft to drive a fan rotor. The fan rotor delivers a source of air across a primary heat exchanger positioned between the inlet and the air cycle compressor. The air cycle compressor and the first turbine are formed of a metal. The second turbine and the fan rotor are formed of non-metallic materials.