Direct Drive Starter Generator for Turbines
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Solution Overview
Problem
Existing motor-generator systems for gas turbines are cumbersome due to multiple gear interfaces, high-speed bearings, and associated infrastructure, which increase weight, complexity, and reduce efficiency, and require significant modifications to existing turbines.
Innovation Solution
A turbine starter/generator machine with a ring-shaped stator mounted on an air duct and rotor elements on fan blades, utilizing magnetic interaction to eliminate gear interfaces and high-speed bearings, allowing for a more compact and lightweight design that can be easily retrofitted to existing turbines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional motor-generator systems with gear interfaces and high-speed bearings are used, then the turbine can be started and generated, but the weight and complexity increase significantly
Solution Approach 1:
The patent replaces the traditional mechanical gear interface and high-speed bearing system with a direct-drive configuration where the rotor is directly coupled to the turbine shaft. This eliminates the need for intermediate mechanical components, reducing weight and complexity while maintaining the turbine starting and generation capabilities through direct electromagnetic coupling.
Solution Approach 2:
The patent extracts and removes the gear interfaces and high-speed bearings from the motor-generator system, retaining only the essential electromagnetic components (stator and rotor) that are directly coupled to the turbine. This extraction eliminates unnecessary mechanical intermediaries that contribute to weight and complexity.
2Reliability
If traditional motor-generator systems with multiple gear interfaces are used, then the turbine can be started, but the device complexity increases
Solution Approach 1:
The patent substitutes the complex mechanical gear train with a direct electromagnetic drive system. The stator windings directly generate rotational force on the rotor, which is coupled to the turbine shaft, eliminating multiple gear interfaces and associated mechanical complexity while preserving the turbine starting function.
Solution Approach 2:
The patent merges the motor and generator functions into a single integrated direct-drive unit that couples directly to the turbine shaft. This consolidation eliminates the need for separate mechanical transmission systems, reducing device complexity while maintaining both starting and generation capabilities.
3Reliability
If traditional motor-generator systems are used, then the turbine can operate, but significant modifications to existing turbines are required
Solution Approach 1:
The patent designs a universal direct-drive motor-generator unit that can be adapted to various turbine configurations without requiring significant modifications to the existing turbine structure. The standardized stator-rotor assembly with direct shaft coupling can be retrofitted to different turbine types, enhancing ease of manufacture and installation.
Solution Approach 2:
Instead of modifying the turbine to accommodate a traditional motor-generator system with gear interfaces, the patent inverts the approach by using a direct-drive configuration that couples to the turbine shaft directly. This reversal of the traditional integration method minimizes modifications required to existing turbines.
4Reliability
If high-speed bearings and gear interfaces are used, then the motor-generator can function, but the mass of high-speed components increases
Solution Approach 1:
The patent extracts and removes high-speed bearings and gear interfaces from the motor-generator system, retaining only the essential electromagnetic components. This extraction eliminates heavy mechanical support structures and intermediate components, reducing the mass of high-speed components while maintaining motor-generator functionality through direct electromagnetic coupling.
Solution Approach 2:
The patent substitutes the mechanical bearing and gear support structures with a direct-drive electromagnetic system. The rotor is directly coupled to the turbine shaft without intermediate mechanical components, eliminating the need for heavy high-speed bearings and their associated support infrastructure, thereby reducing the mass of high-speed components.
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 solution reduces the mass of high-speed components, minimizes the impact of hot gases on the electric motor, and enhances electrical power generation, enabling more efficient and reliable operation with fewer modifications, particularly suited for large jet turbines.
Implementation Method 1
wherein said stator elements are mounted on said at least one air duct and said rotor elements are mounted on said at least one fan blade; whereby said stator elements magnetically interact with said rotor elements
Data Source
AI summary
A starter/generator machine for a turbine with a turbine enclosure, an air duct, and a plurality of fan blades is provided. The starter/generator machine includes a plurality of stator elements spaced at intervals in a ring shape adjacent to the air duct and a plurality of rotor elements mounted on the fan blades. The stator elements and the rotor elements are mounted to interact magnetically to exert a force sufficient to move the rotor elements. The stator elements are shaped to minimize air flow interference and are formed with a core, at least one pole, and multiple windings. The spacing between the stator elements and the rotor elements forms an air gap on the order of 5-10 mm, and the number of stator elements is different from the number of rotor elements.