Modular Stator Segment with Integrated Cooling for Gas Turbine Maintenance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The size and weight of electrical rotors and stators in gas turbine engines make maintenance difficult, and the magnetic forces between stator and rotor segments complicate removal and installation, while the coolant systems add weight and complexity, requiring additional housing to separate coolant flow from oil.
Innovation Solution
An electromagnetic component for the stator segment with a magnetic flux guide, electrical winding, fluid pathway, and connectors, housed in a non-magnetic casing with a mounting arrangement that allows for easy handling and connection of electrical and fluid pathways, minimizing magnetic flux between segments and providing a fault-tolerant design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the stator is designed as a single large component housed within the engine structure, then the electrical machine can be efficiently packaged, but the size and weight make removal and installation for maintenance difficult
Solution Approach 1:
The stator is divided into multiple modular stator segments that can be independently removed and installed. Each segment contains its own electromagnetic components, windings, and cooling pathways, allowing maintenance personnel to replace individual segments rather than the entire stator assembly, thereby improving maintenance accessibility while maintaining packaging efficiency
2Adaptability or versatility
If the stator and rotor are kept as integrated components within the bearing housing, then efficient packaging is achieved, but magnetic forces between them complicate removal and installation
Solution Approach 1:
By segmenting the stator into separate modules, the magnetic circuit is broken into discrete segments. Each stator segment interacts magnetically only with the rotor locally, reducing the cumulative magnetic force that would exist in an integrated design. This allows easier removal and installation while maintaining effective space utilization within the bearing housing
3Temperature
If a coolant system is added to provide cooling flow through the stator, then thermal management is improved, but weight and complexity increase
Solution Approach 1:
The cooling pathways are integrated directly into the stator segment structure itself, with coolant channels formed within the segment housing and magnetic core. The electrical terminals and fluid connectors are combined into a single connector assembly that engages in one action. This merging of functions improves thermal management while minimizing additional weight and complexity
4Temperature
If a coolant system with additional housing is provided to separate coolant flow from oil, then thermal management is achieved, but weight and complexity increase
Solution Approach 1:
The stator segment housing serves dual purposes: it contains the electromagnetic components and simultaneously houses the integrated cooling pathways. The connector assembly provides both electrical terminals and fluid connectors in a single component. This eliminates the need for separate additional housing to contain coolant, reducing weight while maintaining effective thermal management
Solution Approach 2:
The stator segment housing is designed as a multi-functional component that provides structural support, contains magnetic components, and houses cooling pathways. The connector assembly provides both electrical and fluid connection functions. This multi-functionality eliminates the need for separate dedicated cooling housing, reducing overall weight
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
Enables lighter, easier handling and maintenance of stator segments with reduced magnetic forces, improved thermal management, and inherent fault tolerance by containing defects within each segment, allowing for single-action installation and removal without additional housing.
Implementation Method 1
an electrical winding for electromagnetic interaction with the magnetic flux guide
Implementation Method 2
the coolant which flows along the cooling pathway is in thermal contact with one or both of the winding and the magnetic flux guide
Data Source
AI summary
An electromagnetic component for mounting in a framework 47 so as to provide a stator segment 20 of an electrical machine 12. The component comprises a magnetic flux guide 32 and an electrical winding 34 for electromagnetic interaction with the magnetic flux guide 32. The component further comprises electrical terminals 52 for connecting the electrical winding 34 to an electrical network 61, at least one fluid pathway 42 for receiving a flow of cooling fluid in normal use, and at least one fluid connector 54 for coupling the fluid pathway 42 to a source of cooling fluid.