Rotor Assembly Cooling via Segmented Conduits
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Solution Overview
Problem
Aircraft generator systems, particularly those in high-temperature environments, face increased cooling requirements due to operating conditions, which existing systems struggle to efficiently address, leading to potential thermal management issues and reduced efficiency.
Innovation Solution
A rotor assembly with a dual coolant conduit system where one conduit is thermally conductive with the underlying portion of the rotor windings and another with the overlying portion, connected by radial openings, enhances heat transfer and removal through a fluid coolant flow, effectively addressing the cooling needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a wet cavity system is used to cool the rotor assembly, then cooling effectiveness is improved, but system size, weight, and complexity increase
Solution Approach 1:
The cooling system is segmented into multiple independent coolant conduits (first coolant conduit and second coolant conduit) positioned at different locations within the rotor assembly. Each conduit serves a specific cooling zone, allowing the system to achieve effective cooling without requiring a complete wet cavity immersion system, thus reducing overall system complexity while maintaining temperature control
Solution Approach 2:
Coolant conduits are introduced as intermediary elements that mediate between the heat-generating rotor windings and the external cooling system. These conduits provide targeted thermal management at critical locations without requiring the rotor to be immersed in coolant, thereby achieving cooling effectiveness while avoiding the complexity of a full wet cavity system
2Temperature
If a wet cavity system is used to cool the rotor assembly, then cooling effectiveness is improved, but weight increases
Solution Approach 1:
The cooling system is divided into discrete coolant conduits positioned only where heat generation occurs, rather than immersing the entire rotor assembly in coolant. This segmented approach reduces the amount of coolant and cooling infrastructure required, thereby reducing system weight while maintaining effective cooling at critical thermal zones
Solution Approach 2:
Cooling is applied locally at specific high-heat-generation zones within the rotor assembly through strategically positioned coolant conduits, rather than applying cooling uniformly throughout the entire rotor. This localized approach reduces the overall cooling system mass while maintaining cooling effectiveness where it is most needed
3Temperature
If cooling requirements are increased for high-temperature environments, then thermal management is improved, but device complexity increases
Solution Approach 1:
The cooling system is segmented into multiple independent coolant conduits positioned at different locations within the rotor assembly. Each conduit serves a specific cooling zone, allowing the system to achieve effective cooling without requiring a complete wet cavity immersion system, thus reducing overall system complexity while maintaining temperature control
Solution Approach 2:
The coolant conduits are designed to serve multiple functions: they provide thermal management for the rotor windings, structurally integrate with the rotor assembly, and can be configured to adapt to different operating temperature conditions. This multi-functionality reduces the need for additional dedicated cooling components, thereby managing thermal requirements without proportionally increasing system complexity
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 configuration significantly improves thermal conduction, allowing for higher power generation and efficiency without the need for a wet-cavity system, reducing size, weight, and maintenance while increasing reliability and power density.
Implementation Method 1
Heat from the winding is transferred by conduction to the first and the second coolant conduits
Data Source
AI summary
A method and apparatus for cooling a rotor assembly includes a rotor core having a rotatable shaft and defining at least one rotor post, a winding wound around the post, and at least one coolant conduit supported by the rotor core and in a thermally conductive relationship with a portion of the winding.