Generator Connection Manifold for Cooling and Service Access
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Solution Overview
Problem
Incorporating an electrical machine into a gas turbine engine for power generation poses challenges related to size, weight, accessibility, and aerodynamic performance, particularly when the generator assembly is positioned in a hot portion of the turbine engine, requiring efficient cooling and maintenance access without compromising engine performance.
Innovation Solution
The integration of a stator assembly with a manifold that combines electrical and coolant connections, routing electrical connection lines through cooling ducts to facilitate cooling and reduce thermal insulation needs, while positioning the generator assembly in the aft portion of the engine for accessibility and using a generator coupler to collocate coolant and electrical connections, allowing for non-invasive maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the generator assembly is positioned in the hot portion of the turbine engine for compact integration, then the engine size is reduced, but the generator assembly requires efficient cooling and thermal insulation which increases system complexity
Solution Approach 1:
The patent combines the electrical connection lines with the cooling ducts, routing both electrical conductors and coolant flow through the same structural pathways. This integration eliminates separate cooling infrastructure, reducing overall system complexity while maintaining compact engine design.
Solution Approach 2:
The cooling ducts serve dual functions: they provide thermal management for the generator assembly and simultaneously serve as conduits for electrical connections. This multi-functionality reduces the number of separate systems needed, addressing the complexity issue while maintaining compact integration.
2Volume of moving object
If the generator assembly is positioned in the hot portion of the turbine engine for compact integration, then the engine size is reduced, but the maintenance accessibility is compromised
Solution Approach 1:
The generator assembly is designed as a separable module that can be independently removed from the turbine engine. The stator assembly and rotor assembly are configured to detach without requiring disassembly of surrounding engine components, enabling maintenance accessibility despite compact positioning.
Solution Approach 2:
The generator assembly is positioned and configured to be extractable from the turbine engine without removing other engine components. The coupling mechanism allows the generator to be taken out for maintenance while the engine remains intact, resolving the accessibility issue.
3Productivity
If the generator assembly is positioned in the hot portion of the turbine engine, then aerodynamic performance is enhanced, but thermal management becomes more challenging
Solution Approach 1:
The electrical connection system and cooling system are merged into shared pathways, where cooling ducts also serve as electrical conduits. This integration provides efficient thermal management for the generator assembly while maintaining the compact configuration needed for aerodynamic performance.
Solution Approach 2:
The patent uses fluid-based cooling (coolant flow through ducts) to manage thermal conditions in the hot portion of the engine. The hydraulic/pneumatic cooling system efficiently removes heat from the generator assembly, addressing thermal management challenges while preserving aerodynamic performance.
4Reliability
If separate electrical and coolant connections are used for the generator assembly, then connection reliability is improved, but the device complexity and weight increase
Solution Approach 1:
Electrical connection lines and coolant flow paths are combined within shared structural ducts. This integration maintains reliable connections for both electrical and thermal functions while reducing the number of separate connection systems, thereby lowering overall complexity and weight.
Solution Approach 2:
The connection system is designed with multi-functionality, where the same structural pathways handle both electrical conduction and coolant flow. This universal approach ensures reliable connections for multiple functions simultaneously while minimizing the number of separate components needed.
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 reduces the weight and size of the generator assembly, enhances aerodynamic performance, and enables efficient maintenance by providing cooling for electrical connections and allowing access without disrupting the propulsion engine's operation, thus improving overall system efficiency and accessibility.
Implementation Method 1
routing electrical connection lines through cooling ducts to facilitate cooling
Data Source
AI summary
A generator assembly includes a stator assembly coupled to an engine stator component of a propulsion engine, the stator assembly including: a stator support structure fixedly attached to the engine stator component; a stator disposed on a supporting surface of the stator support; a manifold coupled to the stator support, the manifold defining a connection volume and including at least one coolant opening at a connection end of the manifold; and an electrical connector extending between the stator and a connection device disposed on the connection end. The generator assembly also includes a rotor assembly comprising a rotor support structure connected to a shaft of the propulsion engine and a rotor attached to the rotor support structure, wherein the rotor rotates in conjunction with the shaft to generate a power signal that travels through the electrical connector to the connection device.