Electric Machine Cooling Loop Using Bypass Duct Heat Rejection
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Solution Overview
Problem
The high temperatures in the exhaust/tail cone area of aircraft gas turbine engines pose challenges for the design and operation of electric machines and cooling systems, leading to increased costs and potential performance and durability issues.
Innovation Solution
A cooling system for a gas turbine engine that utilizes a dielectric coolant fluid circulating through a coolant circuit with an evaporator and condenser, where the evaporator is in thermal communication with the electric machine and the condenser is in thermal communication with the bypass duct, allowing for efficient heat transfer and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If an electric machine is positioned in the exhaust/tail cone area of the aircraft engine, then hybrid heat/electric functionality is achieved and fuel economy is optimized, but temperatures in the area rise significantly leading to design constraints on materials and increased costs
Solution Approach 1:
The cooling system is divided into separate functional components: an evaporator positioned near the electric machine to absorb heat, a condenser located in the bypass duct to reject heat, and interconnected conduits forming a closed-loop coolant circuit. This segmentation allows each component to operate optimally in its specific thermal environment while collectively managing the thermal load of the electric machine.
Solution Approach 2:
A dielectric coolant fluid is introduced as an intermediary substance to transfer heat from the electric machine to the bypass duct airflow. The coolant circulates through the evaporator where it absorbs heat from the electric machine, then travels through conduits to the condenser where heat is rejected to the bypass air, effectively mediating the thermal transfer between these two components.
2Reliability
If conventional cooling systems are used in high temperature areas, then cooling function is provided, but material costs increase and performance and durability are affected
Solution Approach 1:
The system changes the thermal parameters of the electric machine environment by actively removing heat through the evaporator, maintaining the electric machine at optimal operating temperatures despite the high-temperature exhaust/tail cone environment. This parameter control enables the use of standard materials rather than expensive high-temperature resistant materials.
Solution Approach 2:
The dielectric coolant fluid utilizes phase transitions (evaporation and condensation) to efficiently transfer heat. The coolant evaporates in the evaporator absorbing latent heat from the electric machine, then condenses in the condenser releasing latent heat to the bypass duct airflow. This phase change mechanism provides high heat transfer efficiency with simple component 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
The cooling system effectively manages the high temperatures around the electric machine, enhancing its performance and durability while reducing material costs and environmental impact.
Implementation Method 1
the evaporator is in thermal communication with the electric machine
Implementation Method 2
the condenser is in thermal communication with the bypass duct
Data Source
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AI summary
A gas turbine engine (10) has an air mover (12) configured for generating a flow of air around a rotation axis (11); a surface (34) extending around the rotation axis delimiting a passage (32) for the flow of air downstream of the air mover (12); an electric machine (40) disposed within the passage (32) and coupled to the air mover (12); a coolant circuit (102) having: an evaporator (104) circumferentially disposed around at least part of the electric machine (40) and in thermal communication therewith; a condenser (106) having a surface cooler (108) circumferentially disposed at least partially around the surface (34) and in thermal communication therewith; a first conduit(110) fluidly connecting an upper region (104a) of the evaporator (104) to an upper region (104a) of the condenser (106); and a second conduit (112) fluidly connecting a lower region (106b) of the condenser (106) to a lower region (104b) of the evaporator (104); and a coolant fluid (120) in the coolant circuit (102).