In-Engine Electric Machine Replacement via Segmented Mounts
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Solution Overview
Problem
The challenge in aircraft propulsion systems is the limited electrical power provided by auxiliary generators in gas turbine engines, which is insufficient for driving electric fans, and the frequent need to replace embedded electric machines, requiring timely and costly disassembly of the engine for maintenance.
Innovation Solution
A method for maintaining and replacing the electric machine within a gas turbine engine in situ, involving the removal of rotor and stator mounts, disconnecting from the electric communication bus, and installing a new electric machine, facilitated by a cover assembly and quick release electric connections, allowing for in-engine replacement without full disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If auxiliary generators are positioned within the gas turbine engine to provide electrical power, then the electrical power is available for driving electric fans, but the amount of electrical power provided is insufficient for adequately driving the electric fan
Solution Approach 1:
The patent combines the generator with the gas turbine engine by positioning the generator within the engine structure, specifically utilizing the engine's rotational components to drive the generator. This merging allows the generator to be powered directly by the engine's operation, providing electrical power for electric fans while being integrated into the existing propulsion system.
2Power
If electric machines are embedded within the gas turbine engine to provide sufficient electrical power, then adequate power for electric fans is achieved, but the electric machines need to be repaired or replaced more frequently than the gas turbine engines
Solution Approach 1:
The patent segments the generator into a separate, modular component that can be independently accessed and replaced. The generator is positioned within the engine structure but designed as a distinct unit with its own mounting system, allowing it to be removed and replaced without replacing the entire gas turbine engine, thus addressing the reliability concern through easier maintenance.
Solution Approach 2:
The patent extracts the generator from the core gas turbine engine structure by providing a removable mounting arrangement. The generator can be taken out as a separate component for maintenance or replacement, while the rest of the engine remains intact. This extraction approach allows the less reliable component (generator) to be serviced independently from the more reliable engine.
3Power
If electric machines are embedded within the gas turbine engine, then sufficient electrical power is provided, but the gas turbine engine must be taken off wing and disassembled to replace the electric machine
Solution Approach 1:
The patent segments the generator mounting system into separate, accessible components with removable mounts. The generator is positioned within the engine but attached through discrete mounting points that can be quickly detached, allowing the generator to be removed without taking the engine off the wing or performing extensive disassembly.
Solution Approach 2:
The patent incorporates preliminary design features in the generator mounting system, such as pre-positioned mounting brackets and quick-release mechanisms, that enable rapid removal and installation. This preliminary preparation of the mounting structure allows maintenance personnel to quickly service the generator without time-consuming disassembly procedures.
4Ease of repair
If the gas turbine engine is disassembled to replace the electric machine, then the electric machine can be replaced, but the replacement process is timely and cost inefficient
Solution Approach 1:
The patent segments the generator and its mounting system into independently serviceable components. The generator is attached to the engine through separate mounting brackets that can be quickly removed, allowing the generator to be replaced as a modular unit without disassembling the entire engine, thus making repair easy and time-efficient.
Solution Approach 2:
The patent incorporates dynamic, removable mounting features that allow the generator to be easily attached and detached. The mounting system includes movable or adjustable components that facilitate quick connection and disconnection, enabling rapid replacement of the generator without time-consuming fastening or alignment procedures.
Data Source
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AI summary
A method (400) is provided for maintaining a gas turbine engine installed on an aircraft, the gas turbine engine including an electric machine mounted at least partially inward of a core air flowpath of the gas turbine engine. The method includes (404) removing a rotor mount connecting a rotor of the electric machine to a rotary component of the gas turbine engine; (410) removing a stator mount connecting a stator of the electric machine to a stationary component of the gas turbine engine; and (414) removing in situ the electric machine.