Inner-Rotor Electrical Machine Integration for Gas Turbine Engines
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Solution Overview
Problem
Incorporating an electrical machine into a gas turbine engine for aircraft propulsion poses challenges related to size, weight, accessibility, and aerodynamic performance, while also requiring effective cooling and maintenance solutions due to high-temperature exhaust gases and complex integration with existing engine components.
Innovation Solution
The electrical machine is designed with a stator assembly coupled to the engine stator component and a rotor assembly connected to the propulsion engine's shaft, allowing for rotational energy exchange and featuring an inner-rotor construction for compactness and accessibility, with a cooling system and sealing mechanisms to manage high-temperature exhaust gases and facilitate maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If an electrical machine is integrated into a propulsion engine, then electrical power generation capability is improved, but device complexity increases
Solution Approach 1:
The electrical machine is integrated into the propulsion engine by merging the rotor assembly with the engine shaft and coupling the stator assembly to engine stator components. This combination allows the electrical machine to utilize existing engine structures, thereby improving power generation capability while managing the increase in device complexity through shared components.
Solution Approach 2:
The electrical machine components serve multiple functions: the rotor assembly not only generates electrical power but also rotates in conjunction with the propulsion engine shaft, while the stator assembly is coupled to engine stator components that may serve both aerodynamic and electrical machine support functions. This multi-functionality helps offset the added complexity.
2Volume of moving object
If the rotor is disposed radially inward of the stator, then compactness is improved, but manufacturing difficulty increases
Solution Approach 1:
The rotor assembly is disposed radially inward of the stator assembly, with the rotor support structure connected to the engine shaft and the rotor itself positioned within the radial space defined by the stator. This nested arrangement achieves compactness by utilizing the radial space efficiently, while the modular rotor support structure facilitates manufacturing and assembly.
Solution Approach 2:
The electrical machine is divided into separate rotor and stator assemblies, each with its own support structure. The rotor assembly can be manufactured and assembled separately from the stator assembly, allowing for specialized manufacturing processes for each component while achieving the compact radial arrangement when integrated.
3Ease of operation
If the stator assembly is coupled to engine stator components, then ease of installation is improved, but aerodynamic performance may deteriorate
Solution Approach 1:
The stator assembly is coupled to existing engine stator components, merging the electrical machine mounting function with the aerodynamic stator structure. This integration simplifies installation by utilizing already-present structural elements, while care is taken to ensure the coupling does not significantly interfere with the aerodynamic flow paths.
Solution Approach 2:
The stator support assembly is designed to provide structural support for the electrical machine stator while maintaining local aerodynamic quality in the engine stator components. The coupling is arranged to minimize disruption to airflow, ensuring that the electrical machine integration does not significantly degrade aerodynamic performance.
4Reliability
If cooling and sealing mechanisms are added, then reliability is improved, but device complexity increases
Solution Approach 1:
Cooling and sealing mechanisms are integrated into the existing electrical machine and propulsion engine structures. The cooling system utilizes available coolant pathways, and sealing mechanisms are incorporated into the bearing support frame and shaft connections, thereby improving reliability without adding separate, standalone cooling and sealing systems that would significantly increase complexity.
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 design enhances the compactness and operability of the electrical machine, improves accessibility for maintenance, and effectively manages high-temperature exhaust gases, ensuring efficient energy conversion and reduced risk of component damage, while maintaining the propulsion engine's performance.
Implementation Method 1
The rotor exchanges rotational energy with the shaft to operate as either an electrical motor or an electrical generator
Implementation Method 2
featuring a cooling system and sealing mechanisms to manage high-temperature exhaust gases
Implementation Method 3
sealing mechanisms to manage high-temperature exhaust gases
Data Source
AI summary
An electrical machine includes a stator assembly coupled to an engine stator component of a propulsion engine. The stator assembly includes a stator support assembly fixedly attached to the engine stator component and a stator disposed on a supporting surface of the stator support structure. The electrical machine also includes a rotor assembly including a rotor support structure connected to a shaft of the propulsion engine and a rotor attached to the rotor support structure such that the rotor is disposed radially inward of the stator. The rotor exchanges rotational energy with the shaft to operate as either an electrical motor or an electrical generator.