Polygonal Cross-Section Fluid Passage Assembly for Aircraft Power Generators
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Solution Overview
Problem
Existing power generator designs in aircraft engines face challenges in efficiently distributing lubrication and coolant fluids due to complex routing requirements, often resulting in the need for intricate and heavy fluid passage assemblies with internal supports that increase weight and reduce fuel efficiency.
Innovation Solution
A fluid passage assembly with a polygonal cross-section, specifically a diamond shape, is integrated into the generator housing, allowing for additive manufacturing without internal supports, which enhances structural integrity and reduces weight by eliminating the need for support devices, thereby optimizing fluid flow and mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fluid passage assemblies are used with complex routing, then fluid distribution function is achieved, but weight increases and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple fluid passage functions (lubrication distribution and coolant distribution) into a single integrated fluid passage assembly. The generator housing serves dual purposes as both structural component and fluid distribution system, eliminating the need for separate heavy piping and reducing overall weight while maintaining reliable fluid distribution to all necessary locations.
Solution Approach 2:
The generator housing is designed with multi-functionality, serving both as the structural enclosure and as the fluid passage network. The housing incorporates integrated fluid passages that perform multiple functions: structural support, lubrication distribution, and coolant distribution, thereby reducing the need for additional separate components and reducing weight.
2Strength
If traditional fluid passage assemblies with internal supports are used, then structural integrity is maintained, but weight increases
Solution Approach 1:
The structural housing and fluid passage network are merged into a single integrated component. The housing walls themselves form the fluid passages, eliminating the need for separate internal support structures and piping. This integration maintains structural integrity while removing unnecessary weight from separate support components.
3Productivity
If additive manufacturing is used for fluid passage assembly, then manufacturing efficiency improves and weight reduces, but manufacturing complexity increases
Solution Approach 1:
The integration of multiple fluid passage functions into a single housing component creates a complex geometry that is ideally suited for additive manufacturing. The polygonal cross-sections with flat surfaces and corners are well-suited for additive manufacturing processes, allowing the complex integrated structure to be manufactured efficiently in a single process without requiring assembly of multiple parts.
Solution Approach 2:
The patent specifies particular geometric parameters (polygonal cross-sections with flat surfaces and corners) that are optimized for additive manufacturing processes. These parameter choices enable the complex integrated structure to be manufactured efficiently using additive techniques, improving productivity despite the inherent manufacturing complexity.
4Productivity
If polygonal cross-section conduits are used, then additive manufacturing efficiency improves, but fluid flow characteristics may be affected
Solution Approach 1:
The patent specifies polygonal cross-sections with particular geometric parameters (flat surfaces and corners) that optimize both additive manufacturing efficiency and fluid flow characteristics. The corner radius parameter is controlled to ensure proper material flow during additive manufacturing while maintaining adequate fluid flow paths. The geometric parameters are carefully selected to balance manufacturing efficiency with fluid distribution reliability.
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 solution enables efficient lubrication and coolant distribution while reducing the weight of the power generator, improving specific fuel consumption and manufacturing efficiency through the use of additive manufacturing techniques.
Implementation Method 1
transfer heat in order to maintain a functional temperature for the power generator
Implementation Method 2
coolant distribution
Implementation Method 3
lubrication distribution
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A fluid passage assembly (130) and method for manufacturing a fluid passage assembly (130) for a power generator (10). The fluid passage assembly (130) includes a manifold body having an inlet conduit (134) for receiving a fluid, and at least one distribution conduit (136) fluidly coupled to the inlet conduit (134) for dispensing the fluid to cool the power generator (10), wherein a cross-section of the at least one distribution conduit (136) includes at least one corner (158).