Integrated Generator Manifold for Turbine Engine Cooling
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Solution Overview
Problem
Incorporating an electrical machine into a propulsion engine introduces challenges related to size, weight, accessibility, and aerodynamic performance, particularly when generating electrical power in hot portions of the turbine engine.
Innovation Solution
An integrated generator assembly with a stator assembly that includes a manifold for both electrical and coolant connections, routed through cooling ducts to reduce weight and enhance accessibility for maintenance, and a cooling system that uses coolant to cool electrical connections, reducing the need for thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If electrical connections are routed through hot portions of the turbine engine, then electrical power can be generated from mechanical energy in the propulsion engine, but the electrical connections will be exposed to high temperatures requiring additional thermal insulation
Solution Approach 1:
The patent introduces cooling ducts as intermediary structures that route coolant between the stator assembly and rotor assembly. These cooling ducts create a thermal barrier that protects electrical connections from high temperatures in the turbine engine environment, allowing electrical power generation without excessive thermal exposure.
Solution Approach 2:
The patent employs a hydraulic cooling system where coolant is circulated through cooling ducts to remove heat from electrical connections. This fluid-based thermal management system maintains electrical connections at safe operating temperatures while allowing the generator assembly to function in the high-temperature turbine engine environment.
2Reliability
If separate structures are used for electrical and coolant connections, then each connection type can be optimized independently, but the generator assembly size and weight increase
Solution Approach 1:
The patent merges the electrical connection structure and coolant connection structure into a single integrated manifold assembly. The manifold serves dual functions: providing electrical connection points for power transmission and incorporating cooling channels for thermal management. This consolidation reduces the overall number of components, decreases assembly weight, and simplifies the generator assembly while maintaining reliable electrical and coolant connections.
3Productivity
If the generator assembly is integrated into the propulsion engine, then aerodynamic performance is enhanced and size is reduced, but accessibility for maintenance becomes difficult
Solution Approach 1:
The patent segments the generator assembly into modular components including the stator assembly, rotor assembly, and manifold that can be independently accessed and maintained. The manifold is designed as a separate removable component that provides access points for both electrical and coolant connections, allowing maintenance personnel to service the integrated generator assembly without disassembling the entire propulsion engine.
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 integrated connections facilitate a compact generator assembly that improves aerodynamic performance and accessibility for maintenance, while maintaining electrical connections at a safe temperature without additional insulation, thus enhancing the propulsion engine's efficiency and ease of repair.
Implementation Method 1
a cooling system that uses coolant to cool electrical connections
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.