Rotor Hub Cooling Channels for Lightweight Electric Machines
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Solution Overview
Problem
Gas turbine engine electric machines generate heat during operation, requiring cooling, but external fans used for cooling add weight and modify components, necessitating a lightweight, non-intrusive cooling solution for the magnetic rotor drum.
Innovation Solution
A non-magnetic rotor hub with circumferentially skewed cooling channels is integrated with the magnetic rotor drum, allowing air to be drawn through and cool the rotor drum during rotation, reducing the need for external fans and weight addition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external fans are used to cool the electric machine, then cooling effectiveness is improved, but weight increases and component complexity increases
Solution Approach 1:
The cooling function is merged with the rotor hub structure by integrating cooling channels directly into the hub. This eliminates the need for separate external fans and associated cooling components, thereby reducing overall system weight while maintaining effective cooling of the magnetic rotor drum through the rotor's rotational motion.
Solution Approach 2:
The rotor hub serves its primary structural function of coupling the shaft to the magnetic rotor drum while simultaneously performing the cooling function through its integrated channels. The rotation of the rotor itself generates the airflow needed for cooling, making the system self-sufficient without requiring additional external cooling devices.
2Temperature
If external fans are used to cool the electric machine, then cooling effectiveness is improved, but device complexity increases
Solution Approach 1:
The cooling function is merged with the rotor hub structure by integrating cooling channels directly into the hub. This eliminates the need for separate external fans and associated cooling components, thereby reducing overall system weight while maintaining effective cooling of the magnetic rotor drum through the rotor's rotational motion.
Solution Approach 2:
The rotor hub performs multiple functions: it mechanically couples the shaft to the magnetic rotor drum for rotation, and simultaneously provides cooling pathways through its integrated channels. This multi-functionality reduces the total number of components needed in the system.
3Weight of moving object
If cooling channels are integrated into the rotor hub, then weight is reduced and simplicity is improved, but cooling effectiveness may be compromised
Solution Approach 1:
The cooling channels are arranged in a circumferential pattern around the rotor hub, utilizing the rotational dimension of the rotor to generate centrifugal airflow. This dimensional approach ensures that cooling air reaches all surfaces of the magnetic rotor drum effectively, including areas that would be difficult to cool with linear or axial channel configurations.
Solution Approach 2:
The cooling channels are strategically positioned and oriented to deliver cooling air to specific high-heat-generation areas of the magnetic rotor drum. The channel geometry and distribution are optimized to provide targeted cooling where it is most needed, ensuring effective heat removal despite the integrated design.
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 effectively cools the magnetic rotor drum, extending the operating life of the electric machine while maintaining a lightweight and non-intrusive design, avoiding the weight and complexity of external cooling systems.
Implementation Method 1
The plurality of cooling channels may be skewed circumferentially to cause air to be drawn through the plurality of cooling channels and cool the magnetic rotor drum in response to rotation of the shaft about the axis
Implementation Method 2
air to be drawn through the plurality of cooling channels and cool the magnetic rotor drum
Data Source
AI summary
An electric machine adapted for use in a gas turbine engine includes a shaft extending along a central axis, a magnetic rotor drum, and a non-magnetic rotor hub rotatably coupled with the shaft and the magnetic rotor drum. The magnetic rotor drum includes a rotor and a plurality of magnets arranged circumferentially about the central axis.