Variable Lattice Rotor for Cabin Air Compressor

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Solution Overview

Problem

Traditional rotors for cabin air compressors in aircraft environmental control systems face challenges in managing stress and deflection, leading to reduced efficiency and increased failure rates due to their solid cross-sections and manufacturing processes, which do not allow for optimized mechanical properties.

Innovation Solution

A rotor with a variable lattice structure, manufactured using additive processes, featuring regions of varying density to optimize mechanical properties, reducing stress in high-stress areas and increasing stiffness in deflection regions, thereby enhancing performance and reducing failure rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional solid cross-section rotors are used, then manufacturing simplicity is maintained, but stress and deflection management is insufficient leading to reduced efficiency and increased failure rates

Engineering Contradiction:

Improvefailure rateVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The rotor employs a variable lattice structure where the lattice density varies across different regions of the rotor body. High-density lattice structures are positioned in high-stress areas to enhance strength and reduce failure rates, while lower-density regions maintain manufacturing efficiency. This local differentiation of structural properties directly addresses the contradiction by improving reliability where needed without unnecessarily increasing overall complexity.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The rotor utilizes a composite lattice structure combining different lattice densities within a single component, manufactured through additive processes. This composite approach allows the integration of high-strength regions in critical areas while maintaining overall structural efficiency, thereby improving reliability without proportionally increasing device complexity.

Inventive Principle:

Principle #40Composite materials

2Strength

If uniform high-density lattice structure is used throughout the rotor, then strength is maximized, but weight increases and manufacturing complexity increases

Engineering Contradiction:

Improverotor strengthVSAvoidrotor weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The variable lattice structure applies high-density configurations only in regions requiring maximum strength, such as areas subjected to high centrifugal forces or bending moments. Other regions use optimized lower-density lattices, maintaining sufficient strength while significantly reducing overall rotor weight compared to a uniform high-density structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The lattice density parameter is varied spatially across the rotor structure based on local stress and deflection requirements. This parameter optimization ensures that strength is maximized only where necessary, allowing weight reduction in non-critical regions while maintaining overall rotor strength through strategic high-density zones.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If variable density lattice structure is implemented, then stress and deflection are optimized, but manufacturing complexity increases

Engineering Contradiction:

Improvestress managementVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The additive manufacturing process enables precise control of lattice density parameters through digital modeling and layer-by-layer construction. This manufacturing approach simplifies the production of variable density structures compared to traditional methods, as the complex geometries are built directly from digital designs without requiring complex tooling or assembly operations.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces traditional mechanical manufacturing processes with additive manufacturing technology. This substitution enables the direct fabrication of complex variable density lattice structures that would be difficult or impossible to produce using conventional subtractive or forming methods, thereby improving stress management capabilities while maintaining manufacturing feasibility.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP4148283A1Turbomachinery rotor with variable lattice densities

Publication Date: 2023.03.15 HAMILTON SUNDSTRAND CORP

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Figure 2B

AI summary

A rotor (26) for a rotary machine in includes a hub (100) centered on a central axis and having a disk portion (120) and a shaft portion (118), a blade (102) extending outward from the hub (100), and a variable lattice structure (142) in an interior of the rotor (26). The variable lattice structure (142) includes a first region (150) of the rotor (26) having a first lattice structure and a second region (152) of the rotor (26) having a second lattice structure. The second lattice structure of the second region (152) is denser than the first lattice structure of the first region (150). The second region (152) is a deflection region or a stress region of the rotor (26).