Integrated E-Machine Controller Mounting for Turbomachine Heat Isolation
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Solution Overview
Problem
Conventional turbomachine controllers are heavy, bulky, and inefficient, with thermal conditions affecting their operation, and their manufacture and assembly are difficult.
Innovation Solution
A turbomachine with an integrated controller that is thermally decoupled from high-temperature components using a fastener arrangement, which includes a coolant core for efficient cooling and a thermally insulative heatshield to maintain optimal operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional controllers are used in turbomachines, then control functionality is provided, but the controllers are heavy and bulky
Solution Approach 1:
The controller is integrated directly into the turbomachine housing, merging two separate components (controller and housing) into a single unified structure. This eliminates the need for separate controller mounting brackets and reduces overall weight while maintaining control functionality.
Solution Approach 2:
The housing structure serves dual purposes: it provides mechanical protection for the turbomachine components and simultaneously acts as the controller housing. This multi-functionality reduces the number of separate components needed, thereby reducing weight and simplifying the overall device structure.
2Volume of moving object
If the controller is positioned close to the turbomachine stage, then space is saved, but thermal conditions negatively affect controller operation
Solution Approach 1:
The controller mounting structure is divided into separate sections: a hot section that interfaces with the high-temperature turbomachine environment and a cool section that houses the temperature-sensitive electronic components. This segmentation allows the controller to be positioned close to the turbomachine stage for compactness while maintaining appropriate thermal separation to protect sensitive electronics from excessive heat.
Solution Approach 2:
A thermal barrier or heat shield is introduced as an intermediary element between the hot turbomachine stage and the controller components. This intermediary structure blocks direct heat transfer to the controller, enabling close proximity positioning without exposing sensitive electronics to damaging temperatures.
3Strength
If conventional fastening methods are used to attach the controller, then structural attachment is achieved, but thermal coupling transfers heat to the controller
Solution Approach 1:
The fastening structure utilizes composite construction with thermally conductive materials in regions requiring mechanical strength and thermal resistance in regions exposed to high temperatures. This allows the attachment to maintain structural integrity while blocking heat transfer pathways to the controller.
Solution Approach 2:
Thermal insulation material or heat-blocking structures are incorporated into the fastening arrangement as intermediary elements. These intermediaries maintain the mechanical connection between the housing and controller while preventing direct thermal coupling, thus protecting the controller from heat transfer.
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 solution provides a compact, lightweight, and efficient controller that operates effectively in high-temperature environments, improving manufacturing efficiency and reducing thermal interference.
Implementation Method 1
a fastener arrangement with fasteners that attach a housing of the e-machine to a support structure of the controller. Despite close proximity to the turbine stage, the fastener arrangement thermally de-couples the fasteners from the turbine stage
Implementation Method 2
The integrated controller may include a coolant core that provides efficient cooling to the integrated controller
Data Source
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AI summary
A turbomachine (1100) includes a housing (1118) and a rotating group that is supported for rotation about an axis of rotation (1104) within the housing. The turbomachine also includes a turbomachine stage including a wheel of the rotating group supported within a turbomachine housing of the housing. The turbomachine further includes an e-machine section including an e-machine (1114) that is housed within an e-machine housing of the housing. The e-machine is operably coupled to the rotating group and configured to operate as at least one of a motor and a generator. Moreover, the turbomachine includes an integrated controller (1150) that extends in a circumferential direction about the axis of rotation. The integrated controller is configured for controlling the e-machine. Additionally, the turbomachine includes a thermally decoupled fastener arrangement (1158) that attaches the integrated controller to the e-machine housing. The fastener arrangement thermally decouples the integrated controller from the turbomachine stage.