Generator Thermal Management via Bypass Air Coupling
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Solution Overview
Problem
Throttle loss recovery systems face challenges in managing generator temperatures, as the heat generated from electrical energy production can exceed the maximum operating temperatures of components under the hood of a vehicle, leading to inefficiencies and potential damage.
Innovation Solution
A turbine assembly with a conductive structure that provides thermal coupling between the generator stator assembly and the bypass fluid flow, allowing for efficient heat transfer from the generator to the cooler bypass air, while an insulating structure radially encompasses the conductive structure and generator to prevent heat transfer to the surrounding environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the generator is used to produce electrical energy from the turbine, then energy recovery from throttled air is improved, but the generator temperature increases and may exceed maximum operating temperatures
Solution Approach 1:
The patent extracts the heat management function from the generator by introducing a separate cooling system that uses bypass air to cool the generator stator assembly independently from the power generation process, allowing energy recovery to continue without temperature constraints
Solution Approach 2:
The patent introduces bypass air as an intermediary cooling medium between the hot generator and the environment. This cooler air flows through the stator assembly to absorb excess heat, transferring thermal energy from the generator to the bypass air without interfering with the electrical energy generation process
2Temperature
If heat is transferred from the generator to the surrounding environment, then generator temperature is reduced, but heat transfer efficiency decreases and surrounding components may be affected
Solution Approach 1:
The bypass air serves multiple functions simultaneously: it provides cooling for the generator stator assembly, recovers energy through the turbine, and can be directed to other thermal management needs in the system. This multi-functional use of the same air stream maximizes heat transfer efficiency without requiring separate cooling systems
Solution Approach 2:
The system uses its own bypass air flow to cool the generator, rather than requiring an external cooling system. The cooler air that bypasses the throttle is self-utilized to remove heat from the generator, creating a self-sufficient thermal management solution that improves overall system efficiency
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
Effectively cools the generator using bypass air, reducing the risk of overheating and maintaining optimal operating temperatures, thereby enhancing the system's efficiency and reliability.
Implementation Method 1
The conductive structure provides thermal coupling between the generator stator assembly and the bypass fluid flow to transfer heat from the stator assembly to the bypass fluid flow
Implementation Method 2
an insulating structure radially encompassing the conductive structure and the generator
Data Source
AI summary
Turbine assemblies, loss recovery systems, and related fabrication methods are provided for managing temperatures associated with an electrical generator. One exemplary turbine assembly suitable for use in a loss recovery system includes a wheel configured to rotate in response to a portion of a fluid flow bypassing a flow control valve, a generator including a stator assembly disposed about a rotor coupled to the wheel to rotate in response to rotation of the wheel, a conductive structure in contact with the stator assembly, and an insulating structure radially encompassing the conductive structure and the generator. The conductive structure accesses at least a portion of the fluid flow bypassing the flow control valve and impacting the wheel, thereby providing thermal coupling between the stator assembly and the bypass fluid flow to transfer heat from the stator assembly to the bypass fluid flow via the conductive structure.