Tail Cone Generator Connectors with Integrated Coolant Tube Cooling
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Solution Overview
Problem
Conventional gas turbine engines face challenges in integrating electric generators due to space constraints and high temperatures within the tail cone, which complicates the connection of the low pressure spool to drive accessories effectively.
Innovation Solution
An electric generator system is integrated within the tail cone of the gas turbine engine, operably connected to the low speed spool, utilizing a heat exchanger system with coolant conveying tubes to manage temperature and protect electrical connectors, and a heat rejection heat exchanger to efficiently remove heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If an electric generator is integrated within the tail cone of the gas turbine engine, then space utilization is improved and power generation capability is enhanced, but the high temperature environment in the tail cone creates thermal challenges that worsen the reliability of electrical connectors
Solution Approach 1:
The patent divides the electrical connection system into separate segments: electrical connectors housed within sealed connector housings, individual coolant conduits for each connector, and thermal barriers. This segmentation isolates temperature-sensitive electrical components from the high-temperature tail cone environment while maintaining compact integration.
Solution Approach 2:
Coolant serves as an intermediary substance that transfers heat away from electrical connectors through dedicated coolant conduits. The coolant acts as a thermal mediator between the hot tail cone environment and the temperature-sensitive electrical connectors, preventing direct thermal exposure.
2Device complexity
If electrical connectors are placed in the high temperature tail cone environment to maintain compact design, then device complexity is reduced, but the reliability of electrical connections deteriorates due to thermal exposure
Solution Approach 1:
Electrical connectors are nested within sealed connector housings that are themselves integrated into the tail cone structure. The coolant conduits are nested within or alongside the connector housings, creating a nested arrangement that protects electrical components while maintaining overall system compactness.
Solution Approach 2:
Sealed connector housings act as protective shells that enclose electrical connectors, isolating them from the harsh thermal environment. These housings provide a flexible barrier that maintains electrical connection integrity while allowing the overall system to remain compact and integrated.
3Reliability
If coolant conduits are added to protect electrical connectors from heat, then reliability is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent merges multiple functions into integrated assemblies: connector housings that provide both electrical connection and thermal protection, and coolant conduits that are integrated with rather than separate from the connector structures. This merging reduces overall system complexity compared to having separate protection systems.
Solution Approach 2:
The connector housings serve multiple functions simultaneously: providing electrical connection pathways, sealing against environmental contaminants, and acting as thermal barriers. The coolant conduits serve dual purposes of cooling electrical connectors and potentially cooling other tail cone components, reducing the need for separate cooling systems.
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 configuration allows for effective power generation from the low speed spool, mitigates temperature issues, and ensures reliable electrical connectivity while optimizing space usage within the engine.
Implementation Method 1
a coolant cavity (300) in thermal communication with the electrical connectors and operable to cool the electrical connectors
Implementation Method 2
a heat exchanger system with coolant conveying tubes to manage temperature
Implementation Method 3
a heat rejection heat exchanger to efficiently remove heat
Data Source
Figure 1
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Figure 3
AI summary
A gas turbine engine including: a tail cone (100); a low pressure compressor (44); a low pressure turbine (46); a low speed spool interconnecting the low pressure compressor and the low pressure turbine; and an electric generator (200) located within the tail cone (100), the electric generator (200) being operably connected to the low speed spool, wherein the electric generator includes a coolant cavity in thermal communication with one or more components of the electric generator (200); a structural support housing (280) at least partially enclosing the electric generator (200), the structural support housing (280) including a forward wall located on a forward end of the structural support housing, wherein the forward wall includes a first opening; a first coolant conveying tube (322) extending through the first opening to fluidly connect to the coolant cavity; and a first electrical connector tube (302) extending through the first opening within the first coolant conveying tube (322) to electrically connect to the electric generator (200).