Generator with air-cycle cooling
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Solution Overview
Problem
Cooling high-power output generators in a compact package is challenging due to significant heat dissipation requirements, and existing solutions either rely on inefficient refrigeration cycles or motor-generator systems that do not effectively utilize air-cycle machine output for cooling.
Innovation Solution
An air-cycle machine (ACM) is integrated into the generator cooling assembly, utilizing shaft power from a gas turbine engine to drive air cooling, with a primary and secondary heat exchanger configuration, and optionally including an air/oil heat exchanger and permanent magnet motor-generator to manage temperature and cool generator components efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a refrigeration cycle with air-cycle machine is used to cool the generator, then the generator can be cooled, but the device complexity increases and the package size becomes larger
Solution Approach 1:
The patent combines the ACM cooling system with the generator housing into a single integrated package. The ACM is housed within the generator housing, and the cooling system shares space with the generator components. This merging reduces overall device complexity and creates a compact package that provides both generation and cooling functions in one unit.
Solution Approach 2:
The air-cycle machine serves multiple functions: it cools the generator components, cools the generator oil through the air/oil heat exchanger, and can be integrated with the gas turbine engine's shaft power system. This multi-functionality reduces the need for separate cooling systems, thereby reducing overall device complexity.
2Temperature
If heat sinking with low-temperature coolant is used to manage heat dissipation, then generator components can operate at acceptable temperatures, but the cooling assembly size increases
Solution Approach 1:
The cooling assembly is nested within the generator housing. The ACM compressor, turbine, and heat exchangers are arranged in a compact, nested configuration that utilizes the available space within the generator housing. The air/oil heat exchanger is positioned to utilize the cooled air from the ACM, creating a nested heat exchange arrangement that minimizes volume.
Solution Approach 2:
The patent utilizes three-dimensional space efficiently by arranging cooling components in multiple dimensions within the generator housing. The primary and secondary heat exchangers are positioned to maximize heat transfer surface area within limited space, and the ACM components are arranged vertically and horizontally to optimize space utilization.
3Temperature
If existing refrigeration cycle solutions are used, then cooling can be provided, but the system does not effectively utilize air-cycle machine output for cooling
Solution Approach 1:
The ACM system is driven by shaft power from the gas turbine engine, which is already producing mechanical energy. The system uses its own output (cooled air) to cool the generator components and oil, creating a self-service cooling system that efficiently utilizes the available energy resources without requiring external power sources.
Solution Approach 2:
The system incorporates feedback loops where cooled air from the ACM is directed to cool the generator components, and the temperature conditions are monitored to optimize cooling performance. The air/oil heat exchanger uses the cooled air to cool the generator oil, creating a feedback mechanism that continuously manages thermal conditions.
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 solution provides a compact and effective cooling system that maintains generator components at acceptable temperatures, enhancing operational efficiency and preventing thermal damage in high-power output generators.
Implementation Method 1
The ACM is driven by shaft power from the rotor to be receptive of air, which is cooled by the ACM and output to the generator as fully cooled air to cool the generator
Implementation Method 2
The generator cooling assembly further includes a primary heat exchanger and a secondary heat exchanger
Data Source
AI summary
A generator cooling assembly is provided and includes a rotor, a generator assembly and an air-cycle machine (ACM). The generator assembly includes a generator housing, a generator housed in the generator housing and a shaft coupled to the rotor to transmit shaft power from the rotor to the generator to drive the generator. The ACM is housed in the generator housing and is receptive of air. The air is cooled by the ACM and output from the ACM to the generator as fully cooled air to cool the generator.