Tail Cone Generator Air Cooling to Eliminate Liquid Leakage

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Solution Overview

Problem

Conventional liquid-based cooling systems for aircraft generators suffer from windage losses and require complex support systems, which can reduce operating efficiency and increase the risk of leakage.

Innovation Solution

An air-based cooling system is implemented, where air ducts are used to direct airflow through a generator housing and tail cone, with a plenum connecting the generator to the engine duct, enhancing heat dissipation and eliminating the need for liquid coolant.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a liquid-based cooling system is used, then heat dissipation is achieved, but windage losses increase and operating efficiency decreases

Engineering Contradiction:

Improveheat dissipationVSAvoidoperating efficiency

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The patent replaces the liquid-based cooling system with an air-based cooling system. The air cooling system uses air flow paths and heat exchange surfaces instead of liquid coolant, eliminating windage losses while maintaining effective heat dissipation from the generator components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a pneumatic cooling system using air flow through designated passages. The system utilizes air as the cooling medium, directing it through heat exchange surfaces to remove heat from the generator, thereby avoiding the energy losses associated with liquid coolant flow.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Temperature

If a liquid-based cooling system is used, then cooling function is provided, but device complexity increases due to required support systems

Engineering Contradiction:

Improvecooling functionVSAvoidsupport systems

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the complex support systems required for liquid-based cooling (reservoirs, pumps, heat exchangers) by implementing a simplified air cooling system. The air cooling system uses naturally directed air flow through integrated passages, removing the need for additional cooling-specific components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The air ducting system serves multiple functions: it provides cooling air to the generator, allows heat dissipation, and can be integrated with the existing engine air flow paths. This multi-functionality reduces the need for separate, dedicated cooling system components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If liquid coolant is flowed through generator members, then heat exchange is achieved, but leakage risk increases

Engineering Contradiction:

Improveheat exchangeVSAvoidleakage risk

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent substitutes liquid coolant flow with air flow through the generator housing and passages. Air is used as the cooling medium instead of liquid, eliminating the risk of leakage while maintaining effective heat exchange capabilities through convection and conduction at heat exchange surfaces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Temperature

If liquid-based cooling system is implemented, then cooling capability is provided, but manufacturing complexity increases

Engineering Contradiction:

Improvecooling capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent removes the need for complex manufacturing processes associated with liquid cooling systems (seals, gaskets, pump housings, reservoir integration). The air cooling system uses simpler passages and heat exchange surfaces that can be more easily manufactured and integrated into the generator housing.

Inventive Principle:

Principle #2Taking out (Extraction)

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

This air-based cooling system effectively manages heat loads without the inefficiencies and leakage risks associated with liquid systems, improving the operational integrity and efficiency of aircraft generators.

Implementation Method 1

An air duct extends from the generator, through the generator housing, through the tail cone, and through the engine duct. The air duct includes an opening exposed to an air stream passing over the engine duct.

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

This air-based cooling system effectively manages heat loads without the inefficiencies and leakage risks associated with liquid systems

Methodology Applied

Scientific EffectHeat dissipation: Cooling

Data Source

PatentUS11821370B2Cooling system for tail cone mounted generator

Publication Date: 2023.11.21 HAMILTON SUNDSTRAND CORP

AI summary

An engine system includes an engine duct and a tail cone arranged radially inwardly of the engine duct. The tail cone has an outer surface and an inner surface. A generator housing is arranged in the tail cone. The generator housing includes an outer surface portion spaced from the inner surface of the tail cone. A generator is mounted in the generator housing. An air duct extends from the generator, through the generator housing, through the tail cone, and through the engine duct. The air duct includes an opening exposed to an air stream passing over the engine duct.