Magnetic Coupling Thrust Bearing for Micro-Turbine Shaft

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Solution Overview

Problem

Medium-sized UAVs face short mission times due to low energy density of batteries and inefficiencies of conventional engines at low power levels, necessitating a lightweight, high power density, untethered power source.

Innovation Solution

A micro-turbine alternator system with a magnetic coupling assembly connecting the turbine and compressor shafts, placing an electric generator between two compressor stages to reduce inlet diameter and increase power output, while thermally separating the turbine and compressor sections to prevent demagnetization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a conventional internal combustion engine or jet engine is used for medium-sized UAVs, then power generation is possible, but efficiency is very low at low power levels

Engineering Contradiction:

Improvepower densityVSAvoidenergy efficiency

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent replaces the conventional mechanical connection between turbine and compressor with a magnetic coupling system. The turbine shaft and compressor shaft are coupled through magnetic fields rather than direct mechanical contact, eliminating the need for a traditional engine configuration and enabling more efficient power generation at low power levels suitable for medium-sized UAVs

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Duration of action of moving object

If battery energy density is increased to extend mission time, then mission duration improves, but physical size and weight increase significantly

Engineering Contradiction:

Improvemission timeVSAvoidbattery weight

Core Design Contradiction:

Duration of action of moving objectVSWeight of moving object

Solution Approach 1:

The patent changes the fundamental power generation parameter from chemical energy storage (batteries) to thermal-mechanical energy conversion (micro-turbine). By utilizing a compact micro-turbine alternator system with magnetic coupling, the system achieves high power density and extended mission duration without the weight penalty of high-capacity batteries

Inventive Principle:

Principle #35Parameter changes

3Power

If the electric generator is placed between two compressor stages, then power output increases and inlet diameter is reduced, but thermal management becomes more complex

Engineering Contradiction:

Improvepower outputVSAvoidthermal separation

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The patent segments the power generation system into distinct thermal zones by placing the electric generator between compressor stages. The magnetic coupling allows the turbine shaft and compressor shaft to be thermally separated while maintaining mechanical connection, enabling the generator to be positioned in a cooler zone away from the hot turbine exhaust

Inventive Principle:

Principle #1Segmentation

4Loss of energy

If a magnetic coupling assembly is used to connect turbine and compressor shafts, then mechanical efficiency improves, but manufacturing complexity increases

Engineering Contradiction:

Improvemechanical efficiencyVSAvoidassembly complexity

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The patent introduces a magnetic coupling assembly as an intermediary between the turbine shaft and compressor shaft. This magnetic intermediary transfers rotational power without direct mechanical contact, reducing friction and mechanical losses while the modular design of the magnetic coupler components facilitates assembly

Inventive Principle:

Principle #24Intermediary (Mediator)

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 longer mission times for UAVs by increasing power density and reducing the physical size of the power generation system, while maintaining efficient heat transfer and stability, thus overcoming the limitations of conventional power sources.

Implementation Method 1

The coupling assembly includes a turbine coupler secured to the turbine shaft. The turbine coupler includes a second plurality of magnets having a second magnetic polarity opposite the first magnetic polarity. The magnetic coupling force between the first plurality of magnets and the second plurality of magnets provides an axial clamping force that pulls the turbine coupler toward the generator coupler.

Methodology Applied

Scientific EffectMagnetic coupling force: Magnetism

Data Source

PatentEP4148232B1Thermally isolating, magnetically preloaded and coupled thrust bearing and radial support and shaft assembly

Publication Date: 2024.07.10 HAMILTON SUNDSTRAND CORP

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AI summary

An electrical power generation system including a micro-turbine alternator. The micro-turbine alternator including: a combustion chamber (162), at least one turbine (152, 154) driven by combustion gases from the combustion chamber (162), a first stage compressor (142), and a second stage compressor (144). The first stage compressor (142) and the second stage compressor (144) being operably connected to the combustion chamber (162) to provide a compressed airflow thereto. The micro-turbine alternator including one or more shafts connecting the at least one turbine to the first stage compressor (142) and the second stage compressor (144) such that rotation of the at least one turbine (152, 154) drives rotation of the first stage compressor (142) and second stage compressor (144). The one or more shafts include a turbine shaft (158) attached to the at least one turbine, a compressor shaft (148) attached to the first stage compressor, and a coupling assembly (170) configured to operably connect the turbine shaft to the compressor shaft via a magnetic coupling force.