Multi-Spool Engine Load Balancing Under Thermal Limits

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Solution Overview

Problem

Existing technologies fail to effectively address the need for dynamic electrical load balancing between different spools of a gas turbine engine to optimize fuel burn and improve thermal management system (TMS) performance, especially during ground performance with limited airflow.

Innovation Solution

Implement a system with electrical machines and controllers on both high-pressure and low-pressure spools, utilizing a supervisory controller to dynamically balance electrical loads based on ambient and system thermal conditions, adjusting load levels and current distribution to optimize fuel consumption and reduce thermal impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If electrical machines operate at full performance level during ground performance, then electrical system performance is improved, but thermal management system capability is exceeded due to limited airflow

Engineering Contradiction:
Improveelectrical system performanceVSAvoidthermal management capability
Core Design Contradiction:
ProductivityVSTemperature

Solution Approach 1:

The patent implements dynamic load balancing between high-pressure and low-pressure spool electrical machines based on real-time thermal conditions. The system continuously adjusts the operational load distribution between the two spools to match the available thermal management capacity, which varies with airflow conditions. This dynamic adaptation allows the electrical system to operate at or near full performance while preventing thermal management system overload.

Inventive Principle:
Principle #15Dynamics

2Device complexity

If electrical load is concentrated on a single spool, then electrical system simplicity is improved, but fuel burn optimization is reduced due to limited operational flexibility

Engineering Contradiction:
Improveelectrical system configurationVSAvoidfuel burn
Core Design Contradiction:
Device complexityVSUse of energy by moving object

Solution Approach 1:

The patent divides the electrical load between two separate spools (high-pressure and low-pressure), each equipped with its own electrical machine. This segmentation allows independent control and optimization of each spool's contribution to the total electrical output. By distributing the load rather than concentrating it on a single spool, the system gains flexibility to optimize fuel burn by selecting the most efficient spool configuration for given operating conditions.

Inventive Principle:
Principle #1Segmentation

3Productivity

If thermal management system capacity is increased to support full electrical performance, then electrical system performance is improved, but device complexity and system weight increase

Engineering Contradiction:
Improveelectrical system performanceVSAvoidthermal management system
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent employs a self-regulating thermal management approach where the electrical load distribution automatically adjusts based on the existing thermal management system capacity and real-time thermal conditions. Rather than oversizing the thermal management system to handle maximum possible electrical loads, the system intelligently balances the electrical load between spools to match the actual thermal handling capability. This self-service approach allows full utilization of the existing thermal management infrastructure without requiring additional cooling capacity or system complexity.

Inventive Principle:
Principle #25Self-service

Data Source

PatentUS20260005637A1Multi-spool engine electrical load balancing to optimize fuel burn based on ambient and system thermal conditions
Publication Date: 2026.01.01 HAMILTON SUNDSTRAND CORP
  • US20260005637A1 patent drawing
  • US20260005637A1 patent drawing
  • US20260005637A1 patent drawing

AI summary

A first electrical machine is configured to act as an electrical motor in a first mode and an electrical generator in a second mode. Each first electrical machine is associated with a high-pressure spool of a turbine engine. A first controller is configured to control a load level of the first electrical machine responsive to a first load level control signal. A second electrical machine is configured to act as an electrical motor in the first mode and as an electrical generator in the second mode. The second electrical machine is associated with a low-pressure spool of the turbine engine. A second controller is configured to control a load level of the second electrical machine responsive to a second load level control signal. A third controller is configured to generate the first load level control signal and the second load level control signal responsive to temperatures of the first electrical machine, the first controller, the second electrical machine, and the second controller.