3D Printed Monolithic Aircraft Starter-Generator Housing
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Solution Overview
Problem
Conventional starter/generator apparatuses for aircraft engines are bulky and heavy due to the assembly of numerous separately formed components, which increases weight and cost, necessitating a method to integrate these components into a single unit using three-dimensional printing.
Innovation Solution
The method involves three-dimensional printing of a housing with a cooling jacket that includes one or more cooling passages as a monolithic part of the sidewall, integrating the main stator, main rotor, exciter stator, and exciter rotor into a single component, and eliminating separate bearing assemblies, thereby reducing weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing processes (machining, casting, stamping, stacking) are used to form starter/generator apparatuses, then reliable electrical machines can be formed, but the number of separately formed components increases weight and cost
Solution Approach 1:
The patent applies the merging principle by integrating multiple separately formed components (housing, cooling jacket, bearing assemblies, generator system components) into a single monolithic structure through three-dimensional printing. The cooling jacket is printed as an integral part of the housing sidewall, and bearing assemblies are eliminated by printing bearing surfaces directly onto the housing, reducing the total number of parts and overall weight while maintaining functional reliability.
2Adaptability or versatility
If multiple separately formed components are assembled together to form the starter/generator apparatus, then functional requirements can be met, but the assembly complexity and cost increase
Solution Approach 1:
The patent merges the housing and cooling jacket into a single printed component, eliminating the need for separate cooling jacket assembly. The bearing assemblies are replaced by integrated bearing surfaces printed directly on the housing, further reducing component count and assembly complexity while preserving all necessary functional capabilities of the starter/generator apparatus.
Solution Approach 2:
The monolithic printed housing serves multiple functions simultaneously: it provides structural enclosure, integrates cooling passages through the sidewall, incorporates bearing surfaces for rotor support, and houses the generator system components. This multi-functionality reduces the need for separate specialized components.
3Ease of manufacture
If conventional manufacturing methods are used with separate components, then assembly is possible, but weight and material usage increase
Solution Approach 1:
The patent combines multiple components into a single three-dimensionally printed monolithic structure, eliminating material waste associated with separate manufacturing and assembly processes. The integrated design allows for optimized material distribution throughout the housing, placing material only where structurally necessary while incorporating cooling passages and bearing surfaces without additional material overhead.
Data Source
AI summary
A method for manufacturing a dual-structured aircraft engine starting and generating apparatus is provided. The method includes printing a housing using a three-dimensional printing process including a main machine portion and an exciter portion for receiving at least part of a generator system. Printing the housing includes printing a cooling jacket portion comprising one or more cooling passages that is a monolithic part of a sidewall of the housing.