Rotating Rectifier Assembly for Aircraft Electric Machine
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric machine rectification systems in aircraft are bulky, heavy, and require extensive external circuitry, leading to size, weight, and maintenance challenges, with risks of diode shorting and increased electromagnetic weight due to centrifugal forces.
Innovation Solution
A rotating rectifier assembly with axially aligned diode stacks and conductive segments within a non-conductive shaft tube, providing full wave rectification and reducing external circuitry needs, while using a self-contained cooling system and balanced design for high-speed rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rectification systems are used, then rectification function is achieved, but size and weight increase
Solution Approach 1:
The patent combines the rectifier assembly with the rotor shaft, integrating the rectification function into the rotating component. The rectifier housing is formed as an integral part of the rotor shaft assembly, eliminating separate rectifier housings and reducing overall system weight while maintaining full-wave rectification capability.
Solution Approach 2:
The diode stacks are nested within the rectifier housing that is itself integrated into the rotor shaft. The conductive segments are positioned within the housing to receive rectified current from the diode stacks, creating a compact nested structure that minimizes space and weight while achieving complete rectification.
2Reliability
If conventional rectification systems are used, then rectification function is achieved, but device complexity increases
Solution Approach 1:
The patent extracts the rectification function from external stationary circuitry and relocates it directly onto the rotating rotor shaft assembly. By integrating the rectifier housing, diode stacks, and conductive segments into the rotor, the system eliminates complex external rectifier circuits and associated mounting hardware.
Solution Approach 2:
The rotor shaft assembly serves multiple functions: it provides mechanical rotation, houses the rectification circuitry, and delivers rectified current through its integrated conductive segments. This multi-functionality reduces the need for separate dedicated rectifier components and simplifies the overall system architecture.
3Speed
If diode stacks are exposed to centrifugal forces, then high-speed rotation is achieved, but risk of diode shorting increases
Solution Approach 1:
The rectifier housing provides a protective enclosure for the diode stacks before they are subjected to centrifugal forces during high-speed rotation. The housing acts as a pre-established protective barrier that prevents diode shorting by isolating the diodes from direct exposure to extreme centrifugal effects while allowing the assembly to rotate at high speeds.
Solution Approach 2:
The patent positions the diode stacks and conductive segments in specific three-dimensional arrangements within the rectifier housing that optimize their resistance to centrifugal forces. By carefully designing the spatial configuration and mounting orientation of the diodes, the system maintains reliability under high-speed rotation conditions.
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 achieves reduced size, weight, and maintenance requirements, enhancing reliability and performance by minimizing parts and eliminating external circuitry constraints, resulting in lower operational costs and improved flight efficiency.
Implementation Method 1
a diode stack comprising a first diode seated with the first diode seat and a second diode seated with the second diode seat, each diode having an input electrically coupled with the alternating current output and outputs electrically coupled with each respective conductive segments
Data Source
AI summary
An electric machine assembly, having a first machine providing an alternating current output and a second machine receiving a direct current input, and a rectifier assembly placed within a rotating shaft of the electric machine assembly to convert the AC output of the electric machine assembly to the DC input prior to transmission of the electricity from the electric machine assembly.