Rotating Rectifier Assembly Integrated Within Electric Machine Shaft

Solution Overview

Problem

Conventional generator rectification systems in aircraft electric machines are bulky, heavy, and require external circuitry, leading to size and weight constraints, increased maintenance needs, and risks of diode shorting due to their external placement.

Innovation Solution

A rotating rectifier assembly integrated within the shaft of an electric machine, featuring a conductive frame with axially spaced diodes and bus bars, which converts alternating current to direct current without external circuitry, ensuring rotational balance and reduced centrifugal forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional external rectifier systems are used, then rectification function is provided, but size and weight increase

Engineering Contradiction:

Improverectification functionVSAvoidrectifier assembly weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The rectifier assembly is merged with the rotor assembly by integrating the diodes directly onto the rotor structure. The diodes are mounted on insulating supports that are attached to the rotor, eliminating the need for separate external rectifier housings and circuitry. This integration reduces overall weight while maintaining the rectification function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The rectifier components are nested within the rotor structure. The diodes are mounted on insulating supports that fit within the rotor assembly, with the entire rectifier assembly nested inside the rotor housing. This nesting approach minimizes external space requirements and reduces overall system weight.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If external circuitry is used for rectification, then rectification is achieved, but device complexity increases

Engineering Contradiction:

Improverectification functionVSAvoidexternal circuitry complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The rectifier assembly is merged with the rotor assembly by integrating the diodes directly onto the rotor structure. The diodes are mounted on insulating supports that are attached to the rotor, eliminating the need for separate external rectifier housings and circuitry. This integration reduces overall weight while maintaining the rectification function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The harmful external circuitry is taken out and replaced with a simplified integrated design. The patent extracts the unnecessary external housing, mounting brackets, and complex wiring from the conventional system, retaining only the essential diode rectification elements and mounting them directly on the rotor structure.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If diodes are placed externally, then rectification is provided, but risk of diode shorting increases

Engineering Contradiction:

Improverectification functionVSAvoiddiode shorting risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Insulating supports or insulating structures are introduced as intermediaries between the diodes and the conductive rotor structure. These insulating elements prevent direct electrical contact between the diode terminals and the rotor, eliminating the risk of diode shorting while maintaining mechanical support and electrical connectivity where needed.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If bulky rectifier systems are used, then rectification function is ensured, but maintenance requirements increase

Engineering Contradiction:

Improverectification functionVSAvoidmaintenance requirements

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The rectifier assembly is merged with the rotor assembly by integrating the diodes directly onto the rotor structure. The diodes are mounted on insulating supports that are attached to the rotor, eliminating the need for separate external rectifier housings and circuitry. This integration reduces overall weight while maintaining the rectification function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The harmful external circuitry is taken out and replaced with a simplified integrated design. The patent extracts the unnecessary external housing, mounting brackets, and complex wiring from the conventional system, retaining only the essential diode rectification elements and mounting them directly on the rotor structure.

Inventive Principle:

Principle #2Taking out (Extraction)

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 provides a compact, lightweight, and reliable rectification system with reduced maintenance requirements, enabling high-speed rotation and lower electromagnetic weight, resulting in improved performance, cost-effectiveness, and reduced risk of diode shorting.

Implementation Method 1

a rectifier assembly converting the alternating current output to the direct current input

Methodology Applied

Scientific EffectRectification: Diode

Data Source

PatentUS9490674B2Rotating rectifier assembly for electric machine

Publication Date: 2016.11.08 GE AVIATION SYSTEMS LLC

AI summary

An electric machine having a rectifier assembly placed within a rotating shaft of the electric machine to convert the AC output of the electric machine to the DC input prior to transmission of the electricity from the electric machine.