Integrated Gear Motor Axial Stacking for Compact Starter Generators
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Solution Overview
Problem
Existing mechanical power transmission systems, such as epicyclical gear systems, face challenges in optimizing rotational speed and torque for different operational modes, leading to inefficiencies and increased weight and size in applications like starter/generators and gas-turbine engines, where a single design cannot accommodate varying operational demands.
Innovation Solution
A multi-stage epicyclic gear system is integrated within the housing of a machine, allowing for selective engagement or disengagement of stages to adapt to different operational modes, optimizing rotational speed and torque, and reducing the overall size and weight of the system by utilizing axial stacking and in-rotor configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-stage gear system is used, then the device complexity is reduced, but the adaptability to different operational modes deteriorates
Solution Approach 1:
The gear system is divided into multiple independent stages, each capable of being selectively engaged or disengaged. This segmentation allows the system to provide different gear ratios for different operational modes (e.g., starting mode with higher gear ratio, generating mode with lower gear ratio) while maintaining a relatively simple individual stage design.
Solution Approach 2:
The gear system incorporates dynamic engagement and disengagement mechanisms that allow selective connection of different gear stages based on operational requirements. This dynamic capability enables the system to adapt between different operational modes without requiring complete system redesign, resolving the contradiction between simplicity and adaptability.
2Volume of moving object
If multiple gear stages are integrated within the drum rotor, then the volume of the machine-gear system is reduced, but the manufacturing complexity increases
Solution Approach 1:
The gear stages are nested within the hollow interior space of the drum rotor, utilizing the available volume efficiently. This nesting arrangement reduces the overall machine-gear system volume by placing components within existing structural spaces, while the modular nature of the nested stages helps manage manufacturing complexity.
Solution Approach 2:
The gear stages are arranged axially along the drum rotor interior, utilizing the axial dimension for compact packaging. This dimensional arrangement allows multiple gear stages to coexist within the limited radial space of the drum rotor, reducing overall volume while maintaining manufacturability through standardized axial mounting interfaces.
3Volume of moving object
If the gear system is located within the housing of the machine, then the total volume required is reduced, but the ease of repair deteriorates
Solution Approach 1:
The gear system is extracted from the traditional external housing arrangement and relocated to the interior space of the drum rotor. This extraction into the rotor interior reduces the external footprint and total system volume, while the modular stage design allows for potential extraction during maintenance to facilitate repair access.
Data Source
AI summary
An example machine-gear system that connects to a prime mover in which the prime mover may operate at a first rotational speed and the machine may operate at a different rotational speed. The gear system, of the machine-gear system, may be configured to connect the prime mover and the machine such that the prime mover operates at the first rotational speed and the machine may operate at the different speed. The gear system may be located within the housing of the machine, which may result in a more compact machine-gear system, than for other arrangements. In some examples, the gear system may include two or more stages. In some examples, the multiple stage gear systems may be configured to engage or disengage from one, or more, stages, which may result in a machine-gear system that operates at two or more different rotational speeds as the operational modes change.