Air Cycle Machine Magnetic Gear Coupling With Shaft Stabilization
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Solution Overview
Problem
Conventional air cycle machines for aircraft environmental control systems face inefficiencies due to the need for uniform rotational speeds of compressors and turbines, leading to performance losses and increased system weight, as well as the limitations of air bearings which require cooling and are susceptible to debris.
Innovation Solution
An air cycle machine incorporating an axial flux magnetic gear system that electromechanically couples the turbine and compressor sections, allowing for different rotational speeds and using magnetic bearings for stabilization, eliminating the need for separate cooling ducts and enhancing reliability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If air bearings are used to support and stabilize the shaft, then the shaft can be supported and stabilized, but cooling ducting is required and debris can negatively impact performance
Solution Approach 1:
The patent replaces air bearings (mechanical system requiring cooling ducts) with magnetic bearings (electromagnetic field-based system). The magnetic bearings use electromagnetic forces to support and stabilize the shaft without physical contact, eliminating the need for cooling ducting and reducing susceptibility to debris contamination.
Solution Approach 2:
The patent introduces magnetic fields as an intermediary between the shaft and the bearing structure. Instead of direct mechanical contact or air film requiring cooling, the magnetic field serves as the mediating force to achieve shaft stabilization without the harmful associations of traditional air bearings.
2Device complexity
If the compressor and turbine rotate at the same speed, then the shaft coupling is simplified, but performance efficiency is reduced and system weight increases
Solution Approach 1:
The patent applies dynamic speed control to the compressor and turbine, allowing each component to rotate at its optimal speed independently. The magnetic bearing system enables this dynamic operation by providing stabilization without requiring uniform rotational speeds, thus improving performance efficiency while managing the increased complexity through advanced control capabilities.
Solution Approach 2:
The patent changes the operational parameter of rotational speed from a fixed uniform value to variable independent values for the compressor and turbine. This parameter change allows each component to operate at its peak efficiency point, improving overall system productivity despite the added complexity of speed control.
3Speed
If a booster compressor is added upstream of the turbine, then the desired rotational speed in the compressor section is achieved, but additional system weight is added
Solution Approach 1:
The patent replaces the mechanical booster compressor with an electromagnetic drive system using magnetic bearings. The magnetic bearing system can provide the necessary rotational speed control and torque directly to the compressor, eliminating the need for a separate mechanical booster compressor and reducing overall system weight.
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 enables higher efficiency and reliability with reduced weight and increased operational speeds, as well as improved shaft stabilization without the need for cooling ducts, allowing for optimized performance and reduced maintenance risks.
Implementation Method 1
The first rotor includes a first plurality of magnets arranged radially about a first rotational axis aligned with the stator axis and configured to interact with the stator such that the first rotor rotates at a first rotational speed when the axial flux magnetic gear system is exposed to an electrical current
Implementation Method 2
The winding system stabilizes a position of the first rotor along the first rotational axis and a position of the second rotor along the second rotational axis
Implementation Method 3
a stabilization system for at least one shaft of the air cycle machine
Data Source
Figure 1
Figure 2
Figure 3A~3D
AI summary
An air cycle machine includes a turbine section, a compressor section, an axial flux magnetic gear system electromechanically coupling the turbine section to the compressor section, and a stabilization system for at least one shaft of the air cycle machine. The axial flux magnetic gear system includes a stator (208), two rotors (204, 206), a winding system (214), and a control module (216). Each rotor interacts with the stator such that the rotor rotates when the axial flux magnetic gear system is exposed to an electrical current. The winding system stabilizes the position of the rotors along their rotational axes. The control module is configured to supply the electrical current to at least one of the winding system, the stator, and the rotors to drive rotation of the rotors. The stabilization system stabilizes the position of the at least one shaft of the air cycle machine along the shaft's rotational axis.