Single-Shaft Centrifugal Rotor Integration for Compact Air Cycle Machines
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Solution Overview
Problem
Existing air cycle machines (ACMs) utilize separate rotors for different stages, which can impact efficiency, size, and weight.
Innovation Solution
A single-shaft unitary centrifugal rotor integrates multiple stages into a unified structure, featuring a body, flange, and multiple rotor sections with varying blade profiles and flow paths, along with journal and thrust bearings, and thermal insulation, suitable for both compressor and turbine stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate rotors are used for different stages, then each stage can be optimized independently, but the overall device complexity, size, and weight increase
Solution Approach 1:
The patent combines multiple separate rotor stages into a single unitary rotor assembly where multiple blade stages are mounted on a common shaft. This merging approach reduces the number of separate components while maintaining the ability to optimize each blade stage independently through its own hub and blade configuration, thereby resolving the contradiction between adaptability and device complexity.
Solution Approach 2:
The unitary rotor assembly serves multiple functions simultaneously by integrating multiple blade stages (both compressor and turbine stages) on a single rotor structure. This multi-functional design allows the same rotor assembly to perform compression and expansion functions across different stages, reducing overall device complexity while maintaining stage-specific optimization capabilities.
2Ease of repair
If separate rotors are used for different stages, then maintenance and replacement can be done individually, but the assembly time and operational downtime increase
Solution Approach 1:
The rotor assembly is segmented into modular blade stages, each with its own hub that can be independently removed from the shaft. This segmentation allows individual blade stages to be maintained or replaced without disassembling the entire rotor assembly, enabling quick maintenance while preserving the ability to service individual components.
Solution Approach 2:
The blade stages are designed with pre-configured mounting features and standardized interfaces on their hubs, allowing for rapid attachment and detachment from the shaft. This preliminary design of modular interfaces reduces the time required for assembly and disassembly during maintenance operations.
3Device complexity
If a unitary rotor structure is used, then part count and assembly complexity are reduced, but manufacturing precision requirements increase
Solution Approach 1:
Instead of manufacturing the entire rotor as a single precision-critical piece, the design segments the blade stages into separate modular units that are assembled onto the shaft. This segmentation distributes the manufacturing precision requirements across multiple smaller components rather than demanding extreme precision across one large unitary structure.
Solution Approach 2:
Each blade stage hub is designed with self-aligning features and balancing capabilities that allow the stages to automatically adjust their positions during assembly and operation. This self-service approach reduces the need for high-precision manual alignment during manufacturing and assembly.
Data Source
AI summary
A single-shaft unitary centrifugal rotor for an air cycle machine (ACM), having: a body extending from a body forward end to a body aft end; a flange intermediate the body forward and aft ends; a first rotor extending forward from the flange by a first axial length to a first rotor end at or near the body forward end, the first rotor defining a first hub and a first blade stage extending outwardly from the first hub; a second rotor extending aft from the flange by a second axial length to a second rotor end at or near the body aft end, and defining a second hub and a second blade stage extending outwardly from the second hub; a passage defined through the unitary rotor, between the body forward and aft ends, that receives a drive shaft.