Single-Spool Generator Rotor With Segmented Magnets for MW Power
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Solution Overview
Problem
Conventional aircraft propulsion systems face challenges in generating sufficient electric power without requiring multiple spools or shafts, gears, and/or transmissions, which add weight and complexity.
Innovation Solution
A power generation system driven by a single-spool gas turbine engine, which includes a rotor with larger permanent magnets and a mechanism to hold them in place, allowing for the generation of 1 MW, 1.5 MW, or 2 MW of electric power without additional mechanical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the size of the rotor and/or the strength of the magnetic field is increased to increase output power, then the output power of the electric generator increases, but larger centrifugal forces are generated that tend to separate the permanent magnets from the rotor
Solution Approach 1:
The rotor is segmented into discrete permanent magnet segments that can be independently secured. Each magnet segment is separated by non-magnetic spacers, allowing the rotor to be constructed with multiple smaller magnetic components rather than one large continuous magnet structure. This segmentation reduces the overall centrifugal force on each individual magnet while maintaining the total magnetic field strength needed for high power output.
Solution Approach 2:
The permanent magnet segments are pre-secured to the rotor using bonding agents or mechanical retention features before the rotor reaches operating speed. This preliminary securing action ensures that the magnets are firmly attached and can withstand the centrifugal forces generated during high-speed rotation, preventing separation while allowing the rotor to operate at the speeds necessary for high power generation.
2Force
If multiple spools or shafts, gears, and/or transmissions are used to reduce centrifugal forces by reducing rotational speed, then the centrifugal forces on permanent magnets are reduced, but the weight and support systems increase
Solution Approach 1:
The patent extracts and eliminates the intermediate mechanical components (multiple spools, shafts, gears, and transmissions) from the power transmission system. By directly coupling the turbine rotor to the generator rotor through a single spool, the design removes the unnecessary weight of multiple support systems while maintaining the ability to generate high power through the use of securely retained permanent magnet segments.
3Force
If multiple spools or shafts, gears, and/or transmissions are used to reduce rotational speed of the rotor, then the rotational speed is reduced and centrifugal forces are decreased, but the device complexity increases
Solution Approach 1:
The patent merges the turbine rotor and generator rotor into a single integrated rotating assembly connected by a common spool. This consolidation eliminates the need for multiple separate spools, shafts, and transmission components, significantly reducing device complexity. The direct-drive configuration maintains high power generation capability through the use of permanent magnet segments that are secured to withstand the operational centrifugal forces.
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 system effectively generates high electric power output while reducing weight and complexity by eliminating the need for multiple spools or shafts, and maintaining efficient operation with rotational isolation between the gas turbine engine and the propulsor.
Implementation Method 1
The output power of the electric generator is a function of the size of the rotor and the strength of the magnetic field associated with the electric generator
Implementation Method 2
increasing the size of the rotor and/or the strength of the magnetic field increases the output power of the electric generator. However, increasing the size of the rotor and/or incorporating larger permanent magnets on the rotor produces larger centrifugal forces that tend to separate the permanent magnets from the rotor
Data Source
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AI summary
A power generation system includes a shroud that defines a fluid flow path. A compressor is in the fluid flow path, and a combustor is in the fluid flow path downstream from the compressor. A turbine is in the fluid flow path downstream from the compressor and the combustor. An electric generator is in the fluid flow path upstream from the compressor, and the electric generator includes a rotor coaxially aligned with the turbine.