Segmented Rotary Transformer for Large-Shaft Contactless Power Transfer
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Solution Overview
Problem
Existing power transfer solutions for rotating systems in aircraft turbomachines face challenges such as harsh environments, complex integration, and high maintenance costs, particularly for large diameter shafts, necessitating a reliable and cost-effective contactless power transfer solution.
Innovation Solution
A segmented rotating transformer with interchangeable annular sectors, utilizing outer and inner magnetic cores with expansions to maintain magnetic field continuity, allowing contactless power transfer through electromagnetic induction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a segmented rotating transformer with interchangeable annular sectors is used, then maintenance is facilitated and accessibility is improved, but device complexity increases due to the segmented structure
Solution Approach 1:
The rotating transformer is divided into multiple identical interchangeable annular sectors that can be independently removed and replaced through circumferential access hatches. This segmentation allows maintenance personnel to access and replace individual sectors without dismantling the entire transformer assembly, significantly improving maintenance accessibility while the modularity actually simplifies the overall system architecture.
2Reliability
If outer magnetic cores have expansions at the air gaps to maintain magnetic field continuity, then power transfer reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The magnetic cores feature localized expansions specifically at the air gap regions where magnetic field continuity is most critical. These expansions are concentrated only where needed rather than throughout the entire core structure, maintaining reliable magnetic coupling across the air gap while minimizing the overall manufacturing complexity and material requirements.
3Adaptability or versatility
If the transformer is designed for large diameter shafts, then applicability to aircraft turbomachines is improved, but integration difficulty increases due to confined installation space
Solution Approach 1:
The transformer is segmented into multiple annular sectors that can be installed and removed through circumferential access hatches, enabling integration into confined spaces around large diameter aircraft turbomachine shafts. The modular sectors can be maneuvered into position and assembled in-situ, overcoming the limitations of confined installation spaces while maintaining compatibility with large shaft diameters.
Solution Approach 2:
The segmented transformer design allows components to be nested or stacked in a compact arrangement around the large diameter shaft, with each annular sector fitting within the available radial and axial space. This nested configuration enables the transformer to adapt to the confined installation envelope of aircraft turbomachines while supporting large shaft diameters.
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
Facilitates maintenance, reduces downtime, and enhances reliability and cost-effectiveness by enabling easy integration and replacement of transformer components without interfering with other systems.
Implementation Method 1
each of the elementary stator magnetic circuits including an outer magnetic core and a first electrical winding and each of the elementary rotor magnetic circuits including an inner magnetic core and a second electrical winding to allow a transfer of electrical energy by electromagnetic induction between the outer stator and inner rotor rings
Data Source
AI summary
Rotating transformer intended to be installed around a shaft movable in rotation, the rotating transformer consisting of a plurality of stator annular sectors and a plurality of rotor annular sectors, the juxtaposition of these annular sectors forming a stator ring and a rotor ring consisting of elementary stator and rotor magnetic circuits including outer and inner magnetic cores and first and second electrical windings to allow a transfer of electrical energy by electromagnetic induction between the stator and rotor rings, the inner and outer magnetic cores being separated by the same air gap present on either side of the inner magnetic core and at least the outer magnetic cores have expansions at the level of the air gap to avoid a discontinuity of the magnetic field lines during the rotation of the movable shaft.