Integrated Cooling Fan in a Turbo-Alternator Thrust Runner
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Solution Overview
Problem
Unmanned aerial vehicles (UAVs) and similar systems face short mission times due to low energy density of batteries and inefficiency of conventional engines at low power levels, necessitating a lightweight, high-power-density untethered power source.
Innovation Solution
A high-speed turbo-alternator system with an integrated cooling fan, where the blower blades are internalized within the flange of the thrust bearing runner, providing both cooling for the blower and thrust bearings, and utilizing a micro-turbine alternator to convert fuel into electrical power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional internal combustion engines are used for power generation in UAVs, then power levels can be achieved, but efficiency is very poor at low power levels
Solution Approach 1:
The patent changes the operating parameters by using a micro-turbine alternator that operates at high speeds (e.g., 40,000-100,000 RPM) compared to conventional engines, enabling efficient power generation at low power levels (1-30 KW) while maintaining high efficiency through optimized combustion and power conversion parameters
2Power
If batteries are used for power generation in UAVs, then power levels can be achieved, but energy density is far too low to effectively work in this power range
Solution Approach 1:
The patent replaces the electrochemical energy storage system (batteries) with a micro-turbine alternator system that converts chemical energy from fuel directly to mechanical energy and then to electrical energy, achieving much higher effective energy density and sustained power output for UAV applications
3Duration of action of moving object
If a tethered UAV system is used to increase mission duration, then mission time increases, but operating height and distance are reduced due to tether constraint
Solution Approach 1:
The patent replaces the mechanical tether constraint with a lightweight micro-turbine alternator power source that provides untethered operation, allowing UAVs to achieve extended mission durations while maintaining full freedom of movement in terms of operating height and distance
4Temperature
If blower blades are external to the thrust bearing runner, then cooling can be provided, but device complexity and system size increase
Solution Approach 1:
The patent merges the blower blades with the thrust bearing runner by integrating the blower blade assembly directly into the thrust bearing runner structure, allowing the same rotational component to perform both thrust bearing support and cooling air generation functions, thereby reducing overall system complexity and size while maintaining effective cooling
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 enhances mission duration by providing efficient, untethered, and lightweight power generation, reducing the overall system size and increasing critical speed while effectively cooling the blower and thrust bearings.
Implementation Method 1
a plurality of blower blades located within the flange and defining the radial passageway... providing both cooling for the blower and thrust bearings
Implementation Method 2
an electric generator disposed along the one or more shafts such that electrical power is generated via rotation of the one or more shafts
Data Source
AI summary
A blower including: a forward end; an aft end located opposite the forward end; a shaft located at the aft end; a flange located at the forward end; an internal surface defining an axial passageway within the blower; an external surface radially outward of the internal surface; one or more radial passageway formed within the flange and fluidly connected to the axial passageway, the radial passageway extending from the internal surface to the external surface; and a plurality of blower blades located within the flange and defining the radial passageway.