Geared air cycle machine
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Solution Overview
Problem
Conventional air cycle machines for aircraft environmental control systems face inefficiencies due to operating compressor and turbine components at uniform rotational speeds, leading to performance losses and increased system weight, necessitating additional components like booster compressors.
Innovation Solution
An air cycle machine incorporating an axial flux magnetic gear system electromechanically couples the turbine and compressor sections, allowing for distinct rotational speeds and reducing the need for separate control systems, thereby enhancing efficiency and reliability while minimizing weight and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the compressor and turbine rotate at the same speed (uniform rotational speed), then the system structure is simple, but the performance efficiency decreases and system weight increases
Solution Approach 1:
The patent divides the rotor into multiple independent rotors (first rotor, second rotor, third rotor) that can rotate at different speeds. Each rotor is coupled to the compressor through magnetic gear systems with different gear ratios, allowing the compressor and turbine to operate at their respective optimal speeds independently, thus resolving the contradiction between structural simplicity and performance efficiency.
2Device complexity
If the compressor and turbine rotate at the same speed (uniform rotational speed), then the control system is simpler, but the performance efficiency decreases
Solution Approach 1:
The patent employs magnetic gear systems that inherently provide speed multiplication and torque transmission without requiring external control mechanisms. The magnetic coupling between rotors and the stator automatically achieves the desired speed relationships through magnetic field interactions, eliminating the need for complex electronic control systems while maintaining high performance efficiency.
3Speed
If a booster compressor is added to achieve desired rotational speed, then the rotational speed requirement is met, but the system weight increases
Solution Approach 1:
The patent replaces the mechanical booster compressor with a magnetic gear system that uses magnetic fields for torque transmission and speed multiplication. This substitution eliminates the need for additional mechanical components, reducing system weight while achieving the desired rotational speeds for both compressor and turbine.
4Productivity
If the compressor and turbine operate at different optimal speeds, then the performance efficiency increases, but the system weight increases
Solution Approach 1:
The patent merges the speed control function and torque transmission function into a single magnetic gear system. By combining the magnetic coupling mechanism with the gear ratio arrangement, the system achieves different optimal speeds for compressor and turbine without requiring separate control systems or additional heavy components, thus improving performance efficiency while minimizing weight increase.
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 configuration optimizes rotational speeds for each component, achieves higher efficiency, and reduces system weight by allowing for a wider operating range without stressing magnetic gears, thus improving the overall performance and reliability of the air cycle machine.
Implementation Method 1
The first rotor includes a first plurality of magnets arranged radially about a first rotational axis aligned with the stator axis and configured to interact with the stator such that the first rotor rotates at a first rotational speed when the axial flux magnetic gear system is exposed to an electrical current. The second rotor includes a second plurality of magnets arranged radially about a second rotational axis aligned with the first rotational axis and being configured to interact with the stator such that the second rotor rotates at a second rotational speed when the axial flux magnetic gear system is exposed to the electrical current.
Implementation Method 2
The winding system stabilizes a position of the first rotor along the first rotational axis and a position of the second rotor along the second rotational axis.
Data Source
Figure 1
Figure 2
Figure 3A~3D
AI summary
An air cycle machine includes a turbine section (22), a compressor section (18), and an axial flux magnetic gear system electromechanically coupling the turbine section (22) to the compressor section (18). The axial flux magnetic gear system includes a stator, two rotors, a winding system (214), and a control module (216). The stator includes stator pole sections and is oriented about a stator axis. Each rotor includes magnets arranged radially about a rotational axis which is aligned with the stator axis. Each rotor interacts with the stator such that the rotor rotates at a rotational speed when the axial flux magnetic gear system is exposed to an electrical current. The winding system (214) stabilizes the position of the rotors along their rotational axes. The control module (216) is configured to supply the electrical current to at least one of the winding system (214), the stator, and the rotors to drive rotation of the rotors.