Aircraft Electrical Machine With Non-Contact Cooling Interface

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Solution Overview

Problem

Existing electrical machines in aircraft systems face challenges in efficiently responding to varying power demands while maintaining compact size and effective cooling.

Innovation Solution

The electrical machine incorporates a housing with fluid passages and nozzles that utilize a non-contact interface for fluid flow, coupled with an accessory gearbox that provides cooling fluid, enabling efficient cooling and power generation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If the electrical machine uses traditional contact-based fluid interfaces, then fluid sealing is more reliable, but the size and weight of the machine increase and response speed decreases

Engineering Contradiction:

Improveresponse speed to power demandsVSAvoidfluid interface complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical contact-based fluid interfaces with a magnetic coupling system. The magnetic drive coupling transfers rotational motion and drives the impeller without physical contact between the rotating and stationary parts. This eliminates mechanical seals and contact interfaces, reducing friction, wear, and maintenance while improving response speed and reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a magnetic field as an intermediary between the rotating shaft and the impeller. The magnetic drive coupling creates a magnetic connection that transmits torque without direct mechanical contact, allowing fluid to be pumped efficiently while maintaining isolation between the rotating and stationary components. This intermediary magnetic field resolves the contradiction by enabling power transfer without physical contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Weight of moving object

If the electrical machine incorporates integrated cooling fluid passages and magnetic drive coupling, then size and weight are reduced, but manufacturing complexity increases

Engineering Contradiction:

Improveweight of electrical machineVSAvoidmanufacturing ease

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The patent merges multiple functions into integrated components. The housing incorporates both structural support and integrated cooling fluid passages. The magnetic drive coupling combines the shaft, impeller, and magnetic coupling mechanism into a unified assembly. This consolidation reduces the total number of separate parts, minimizing overall size and weight while eliminating the need for separate sealing mechanisms and external cooling systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing serves multiple functions simultaneously: it provides structural containment, houses the magnetic drive coupling, and incorporates cooling fluid passages for thermal management. The magnetic drive coupling also serves dual purposes by both driving the impeller and providing the sealing function traditionally handled by separate mechanical seals. This multi-functionality reduces component count and overall system weight.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Volume of moving object

If the electrical machine uses compact integrated design, then space efficiency improves, but cooling effectiveness may be compromised

Engineering Contradiction:

Improvevolume of electrical machineVSAvoidcooling effectiveness

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The patent nests the cooling fluid passages within the housing structure and integrates them with the magnetic drive coupling assembly. The cooling channels are embedded within the housing walls and positioned to maximize thermal contact with heat-generating components. The impeller and fluid passages are nested within the housing cavity, creating a compact arrangement where cooling functionality is embedded rather than added as a separate external system.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 allows for faster response to changing power demands, reduced size and weight of the electrical machine, and effective cooling, enhancing the overall performance and efficiency of the aircraft electrical system.

Implementation Method 1

cooling the electric machine with the fluid from the accessory gearbox

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS20250192642A1Electric machine and method of operating aircraft

Publication Date: 2025.06.12 GE AVIATION SYSTEMS LLC

AI summary

An electrical machine comprising a rotatable shaft; an induction generator mechanically coupled to the rotatable shaft and defining a power output connectable with an electrical load, wherein the power output defines a desired constant voltage output; a converter electrically connected with the power output; and a controller connected to the converter, the controller configured to at least one of provide supplemental power at the power output or absorb excess power at the power output.