Epicyclic Geartrain with Integrated Axial Flux Generator
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Solution Overview
Problem
Conventional turbofan engines require additional weight and complexity due to the use of a separate gearbox to drive an electrical generator, which is not efficiently integrated with the epicyclic gearbox, leading to increased weight and complexity.
Innovation Solution
Incorporating permanent magnet portions and stator coil arrays into the existing structural elements of the epicyclic geartrain, forming axial flux electric motor generator elements, which allows for the generation of electrical power without adding bulk, making the system more compact and efficient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a separate gearbox is used to drive an electrical generator, then electrical power can be generated, but weight and complexity increase
Solution Approach 1:
The patent combines the electrical generator with the epicyclic gearbox by integrating the stator assembly into the ring gear and the rotor assembly into the planet carrier. This merging eliminates the need for a separate gearbox to drive the generator, reducing overall device complexity while maintaining electrical power generation capability
Solution Approach 2:
The epicyclic gearbox is designed to serve dual functions: mechanical speed reduction for the fan and electrical power generation. By incorporating motor generator elements directly into the gearbox structure, the system achieves multi-functionality without requiring additional separate components
2Power
If a separate gearbox is used to drive an electrical generator, then electrical power can be generated, but weight increases
Solution Approach 1:
The generator components are merged with existing gearbox structural elements (ring gear and planet carrier), eliminating duplicate materials and reducing overall weight compared to a separate gearbox-generator assembly
3Device complexity
If motor generator elements are integrated into the epicyclic geartrain, then weight and complexity are reduced, but manufacturing complexity increases
Solution Approach 1:
The motor generator elements are segmented into discrete components (stator coils, permanent magnets, rotor windings) that can be manufactured separately and then assembled into the gearbox structure, managing manufacturing complexity through modular assembly
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 integration of electromagnetic elements into the epicyclic geartrain enables the generation of electrical power while reducing weight and complexity, providing a more efficient and compact solution for electrical power generation in turbofan engines.
Implementation Method 1
the planet torque ring is provided with at least one stator coil array, the or each stator coil array being positioned in axial alignment with the or each corresponding plurality of permanent magnet portions as an axial flux electric motor generator element
Data Source
AI summary
An epicyclic geartrain comprises a sun gear, a plurality of planet gears, and a ring gear. The plurality of planet gears is supported by a planet torque ring. The planet gears meshingly surround the sun gear, and the ring gear meshingly surrounds the planet gears. At least one of the sun gear, the plurality of planet gears, and the ring gear, is provided with a plurality of permanent magnet portions. Each of the plurality of magnet portions is arranged as a circumferential array. The planet torque ring is provided with at least one stator coil array, with the or each stator coil array being positioned in axial alignment with the or each corresponding plurality of permanent magnet portions as an axial flux electric motor generator element.