Coaxial Turbine Generator Layout for High-Power Single-Spool Output
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Solution Overview
Problem
Conventional aircraft propulsion systems face challenges in generating high electric power without requiring multiple spools or shafts, gears, and transmissions, which add weight and complexity, especially at high rotational speeds where centrifugal forces separate permanent magnets from the rotor in gas turbine engines.
Innovation Solution
A power generation system that incorporates a single-spool gas turbine engine with an integrally bladed rotor and non-lubricated bearings, where the electric generator is coaxially aligned with the turbine, and uses a shroud to define a fluid flow path, allowing the propulsor to rotate independently and reducing the need for additional mechanical couplings, thus preventing centrifugal forces from separating the permanent magnets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the size of the rotor and/or the strength of the magnetic field is increased to increase output power, then the output power of the electric generator increases, but the centrifugal forces increase causing permanent magnets to separate from the rotor
Solution Approach 1:
The patent merges the permanent magnets directly with the rotor structure to form an integrally bladed rotor (blisk), where the magnets are integral to the rotor body rather than separate components. This integration eliminates the separation issue by making the magnets part of the rotating structure itself, allowing high output power without magnet detachment
2Strength
If multiple spools or shafts, gears, and/or transmissions are used to reduce centrifugal forces, then the centrifugal forces on permanent magnets are reduced, but the weight and device complexity increase
Solution Approach 1:
The patent extracts and eliminates the intermediate mechanical transmission components (multiple spools, shafts, gears, and transmissions) from the system. By using a direct-drive configuration where the turbine rotor directly drives the electric generator rotor, the system achieves high power output without the complexity and weight of multiple transmission stages
3Strength
If multiple spools or shafts, gears, and/or transmissions are used to reduce centrifugal forces, then the centrifugal forces on permanent magnets are reduced, but the weight increases
Solution Approach 1:
The patent removes the heavy mechanical transmission components (multiple spools, shafts, gears, and transmissions) from the system. The direct-drive configuration eliminates the need for these intermediate components, significantly reducing the overall weight of the power generation system while maintaining the ability to generate high power
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
Enables the generation of 1 MW, 1.5 MW, or 2 MW of electric power without additional mechanical components, reducing weight, manufacturing, and maintenance costs, while maintaining efficient operation and reducing the need for internal cooling and lubrication systems.
Implementation Method 1
The working fluid exits the compressor and flows to the combustors where it mixes with fuel and ignites to generate combustion gases having a high temperature, pressure, and velocity
Implementation Method 2
The combustion gases flow to the turbine where they produce work by rotating the turbine
Implementation Method 3
A spool or shaft connects the turbine to a rotor of an electric generator located inside the fuselage of the aircraft. In this manner, the gas turbine engine may also drive the rotor to produce sufficient electricity
Implementation Method 4
a shroud that defines a fluid flow path. A gas turbine engine is in the fluid flow path
Data Source
AI summary
A power generation system includes a shroud that defines a fluid flow path. A gas turbine engine is in the fluid flow path, and the gas turbine engine includes a compressor, a combustor downstream from the compressor, and a turbine downstream from the combustor. An electric generator is in the fluid flow path upstream from and coaxially aligned with the turbine. The turbine includes an integrally bladed rotor.