Integrated Stator Assembly for Aircraft Generator Fault Tolerance

Solution Overview

Problem

Traditional aircraft main electric generators with separate permanent magnet generators (PMGs) for fault tolerance and redundancy add weight and occupy space due to their mechanical separation.

Innovation Solution

A stator assembly with multiple sets of PMG stator windings wound around distinct continuous circumferential portions of the stator core, mechanically and magnetically isolated from each other, allowing for independent power transmission and reducing the need for multiple mechanical packages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple separate PMGs are used for fault tolerance and redundancy, then reliability is improved, but weight and device complexity increase

Engineering Contradiction:

Improvefault toleranceVSAvoidweight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

Multiple separate PMG assemblies are merged into a single integrated PMG stator assembly. The patent combines multiple independent PMG windings (first set, second set, third set) within one stator core, eliminating the need for multiple separate mechanical packages while maintaining fault tolerance and redundancy capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single PMG stator assembly performs multiple functions by incorporating different sets of windings that can independently power different loads. The first set of windings powers the exciter, the second set powers flight computers, and the third set provides additional redundancy, allowing one component to serve multiple purposes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple separate PMGs are used for fault tolerance and redundancy, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvefault toleranceVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple separate PMG assemblies are merged into a single integrated PMG stator assembly. The patent combines multiple independent PMG windings (first set, second set, third set) within one stator core, eliminating the need for multiple separate mechanical packages while maintaining fault tolerance and redundancy capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The stator assembly is segmented into distinct continuous circumferential portions, each containing a separate set of windings. These segments are electrically isolated from each other, allowing independent operation and fault isolation while being part of a unified structure.

Inventive Principle:

Principle #1Segmentation

3Reliability

If separate mechanical packages are used for each PMG, then fault tolerance is achieved, but space occupation increases

Engineering Contradiction:

Improvefault toleranceVSAvoidspace

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

Multiple separate PMG assemblies are merged into a single integrated PMG stator assembly. The patent combines multiple independent PMG windings (first set, second set, third set) within one stator core, eliminating the need for multiple separate mechanical packages while maintaining fault tolerance and redundancy capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Multiple independent winding sets are nested within the single stator core structure. Each set of windings is wound about different continuous circumferential portions of the same stator core, allowing compact arrangement of multiple functional units within a single physical envelope.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 configuration achieves weight savings, structural simplification, cost reduction, and improved reliability by integrating multiple PMGs into a single shaft, ensuring that failure of one PMG does not affect others and allowing specific power outputs to be assigned to critical loads.

Implementation Method 1

The conductive windings can be used to power an exciter stator, flight computers, or other electrical loads

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3599704B1Stator assembly

Publication Date: 2022.02.16 GE AVIATION SYSTEMS LLC

Figure 1
Figure 2
Figure 3

AI summary

A permanent magnet generator (70), includes a cylindrical rotor assembly (72) having a set of circumferentially-spaced permanent magnets (130) arranged at an outer radius of the rotor assembly (72), and spaced from one another by non-magnetic spacing element (134), and a stator assembly (74) configured to coaxially receive the rotor assembly (72). The stator assembly (74) includes a cylindrical stator core (89), a circumferentially spaced set of posts (73) extending from the stator core (89) and defining a set of stator slots (75) between adjacent posts (73), and a set of conductive windings (100) wound about the stator slots (75).