Generator Rotor Winding Retention and Cooling Fixture
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Solution Overview
Problem
High-speed electrical machines in aircraft generators face issues with centrifugal forces causing winding distortion and premature failure due to high current densities, leading to accelerated wear and thermal dissipation.
Innovation Solution
A main stage generator rotor system with a winding retention member that includes an axial containment plate and tensioning apparatus to prevent radial translation of windings, combined with a cooling oil routing system to direct oil flow over the windings, enhancing support and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-speed operation is maintained, then power output is improved, but centrifugal force causes winding distortion and displacement
Solution Approach 1:
The rotor is divided into multiple independent winding-pole sets, each with its own retention member. This segmentation allows each winding set to be independently supported and cooled, preventing distortion while maintaining high-speed operation capability.
Solution Approach 2:
A retention member is introduced as an intermediary component between the winding-pole set and the rotor structure. This retention member provides mechanical support and cooling functions, preventing winding displacement while allowing high-speed rotation.
2Power
If high current density is used, then power density is improved, but component heating increases and accelerates wear
Solution Approach 1:
A cooling oil routing system is integrated into the retention member, using hydraulic flow to remove heat from the windings. Cooling oil is supplied through routing holes and flows over the windings to dissipate heat generated by high current density operation.
Solution Approach 2:
The retention member is designed to perform multiple functions simultaneously: mechanical retention of windings, structural support, and thermal management through integrated cooling oil routing. This multi-functionality allows high current density operation without excessive heating.
3Stability of the object's composition
If winding support structure is added, then winding stability is improved, but device complexity increases
Solution Approach 1:
Multiple functions are merged into a single retention member component: winding retention, structural support, and cooling oil routing. This integration reduces the number of separate parts and simplifies the overall rotor structure while maintaining winding stability.
Solution Approach 2:
The retention member is designed as a multi-functional component that simultaneously provides mechanical support and thermal management. This universality reduces device complexity by eliminating the need for separate cooling systems and support structures.
4Temperature
If cooling system is integrated, then thermal management is improved, but manufacturing complexity increases
Solution Approach 1:
The cooling oil routing holes are integrated directly into the retention member during manufacturing. This merging of cooling system and structural component simplifies manufacturing by eliminating separate assembly steps for cooling channels.
Solution Approach 2:
The retention member serves itself by incorporating cooling oil routing directly into its structure. The component that provides mechanical support also provides thermal management, eliminating the need for separate cooling system installation.
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 confines windings to prevent distortion and failure, while the cooling system reduces thermal stress and enhances efficiency by maintaining contact between oil and windings, thus extending component lifespan and improving system performance.
Implementation Method 1
a cooling oil routing hole whereby cooling oil may travel radially through the axial containment plate
Implementation Method 2
a tensioning apparatus whereby the axial containment plate is retained in position relative to the winding-pole set
Implementation Method 3
Many electrical machines operate at high speeds, so that significant centrifugal force is exerted on components of the electrical machine, such as the windings
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A generator rotor system (2) having various features is disclosed. The generator rotor system (2) has at least one main stage generator rotor (20) with winding-pole sets (40) spaced annularly about the rotor. The tendency of the windings to distort and or displace under the centrifugal force of the spinning rotor is ameliorated by a winding retention member (50) disposed axially outboard of the winding-pole sets. The winding retention member (50) may also have a one or more cooling oil routing hole (56) to enhance the flow of cooling oil among the windings.