Propulsion system for an aircraft
10807729 ยท 2020-10-20
Assignee
Inventors
- Randy M. Vondrell (Cincinnati, OH, US)
- Michael Thomas Gansler (Mason, OH, US)
- Glenn David Crabtree (Oregonia, OH, US)
- Konrad Roman Weeber (Saratoga Springs, NY, US)
Cpc classification
H02K2213/06
ELECTRICITY
B64D27/026
PERFORMING OPERATIONS; TRANSPORTING
F02K3/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02K3/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K5/1732
ELECTRICITY
Y02T50/60
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H02K7/1823
ELECTRICITY
F05D2220/768
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D15/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K1/274
ELECTRICITY
International classification
F02K3/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D15/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K7/18
ELECTRICITY
Abstract
A propulsion system for an includes a combustion engine, a propulsor, and an electric machine configured to either be driven by the combustion engine or configured to drive the propulsor. The electric machine defines an axis. The electric machine includes a rotor extending along and rotatable about the axis, and a stator having a plurality of winding assemblies, the plurality of winding assemblies spaced along the axis of the electric machine, each winding assembly operable with the rotor independently of an adjacent winding assembly during operation of the electric machine.
Claims
1. An aircraft comprising: an aircraft propulsion system comprising a combustion engine, a propulsor, and an electric machine including a generator configured to be driven by the combustion engine and a motor electrically coupled with the generator and configured to drive the propulsor, wherein the combustion engine and the propulsor are mounted on opposing sides of a fuselage, the motor further defining an axis and comprising: a rotor extending along and rotatable about the axis; a stator comprising a plurality of winding assemblies, the plurality of winding assemblies spaced along the axis of the motor, each winding assembly operable with the rotor independently of an adjacent winding assembly during operation of the motor, wherein the plurality of winding assemblies includes a first winding assembly and a second winding assembly spaced along the axis of the motor; and an electric power bus, wherein the plurality of winding assemblies are separately in electrical communication with the electric power bus; wherein the aircraft is configured for operating the motor with less than all of the plurality of winding assemblies in the event of a failure of one of the plurality of winding assemblies.
2. The aircraft of claim 1, wherein the stator comprises at least three winding assemblies and up to thirty winding assemblies.
3. The aircraft of claim 1, wherein the rotor is positioned inward of the stator.
4. The aircraft of claim 1, wherein each winding assembly comprises a set of windings dedicated to the winding assembly.
5. The aircraft of claim 1, wherein the combustion engine is an aeronautical combustion engine.
6. The aircraft of claim 1, wherein the plurality of winding assemblies are separately in parallel electrical communication with the electric power bus.
7. The aircraft of claim 1, wherein one or more of the plurality of winding assemblies are selectively in electrical communication with the electric power bus.
8. The aircraft of claim 1, wherein the motor comprises a housing, wherein the rotor and stator are each positioned within the housing.
9. The aircraft of claim 1, wherein the aircraft is configured to selectively disconnect at least one winding assembly of the plurality of winding assemblies of the motor during a failure of the at least one winding assembly, during a low power operation mode, or both.
10. The aircraft of claim 1, wherein the aircraft is configured for selectively operating at least one winding assembly of the plurality of winding assemblies of the motor during a failure of one or more of the other winding assemblies, during an operation mode that uses less electrical power than the motor is capable of generating or needs, or both.
11. The aircraft of claim 1, wherein the first winding assembly has an axial width that is different than an axial width of the second winding assembly.
12. The aircraft of claim 1, wherein the propulsor includes a variable pitch fan having a pitch change mechanism that is configured to alter a pitch of each of a plurality of fan blades of the variable pitch fan.
13. The aircraft of claim 1, wherein the rotor includes a motor core extending axially outward of the plurality of permanent magnets.
14. The aircraft of claim 1, wherein the rotor, the stator, and at least one bearing are all enclosed within a common housing.
15. An aircraft comprising: an aircraft propulsion system comprising an electric power source comprising a combustion engine and an electric generator powered by the combustion engine, the aircraft propulsion system further comprising an electric propulsor assembly comprising a propulsor and an electric motor electrically coupled with the generator and configured to drive the propulsor, wherein the combustion engine and the propulsor are mounted on separate wings, the electric motor defining an axis and comprising: a rotor extending along and rotatable about the axis; a stator comprising a plurality of winding assemblies, the plurality of winding assemblies spaced along the axis of the electric motor, each winding assembly operable with the rotor independently of an adjacent winding assembly during operation of the electric motor, wherein the plurality of winding assemblies includes a first winding assembly and a second winding assembly spaced along the axis of the motor, and wherein the rotor comprises a plurality of permanent magnets, and wherein the plurality of permanent magnets extend continuously between the first winding assembly and the second assembly along the axis; and an electric power bus, wherein the plurality of winding assemblies are separately in electrical communication with the electric power bus, and wherein the aircraft is configured for operating the motor with less than all of the plurality of winding assemblies in the event of a failure of one of the plurality of winding assemblies.
16. The aircraft of claim 15, wherein one or more of the plurality of winding assemblies are selectively in electrical communication with the electric power bus.
17. The aircraft of claim 15, wherein the electric motor comprises a housing, wherein the rotor and stator are each positioned within the housing.
18. The aircraft of claim 15, wherein the stator comprises at least three winding assemblies and up to thirty winding assemblies.
19. A propulsion system comprising: a combustion engine mounted to a first wing, a propulsor mounted to a second wing; an electric power bus; and an electric machine including a generator mechanically coupled with the combustion engine and a motor electrically coupled with the propulsor, the motor electrically coupled with the generator and configured to drive the propulsor through the electric power bus, the motor defining an axis and comprising: a rotor extending along and rotatable about the axis; and a stator comprising a first winding assembly and a second winding assembly, the first and second winding assemblies spaced along the axis of the motor and independently operable with the rotor during operation of the motor, wherein the plurality of winding assemblies includes a first winding assembly and a second winding assembly spaced along the axis of the motor, and wherein the rotor comprises a plurality of permanent magnets, and wherein the; wherein the first and second winding assemblies are separately in electrical communication with the electric power bus, and wherein the first winding assembly is selectively in electrical communication with the electric power bus for operating the motor with the second winding assembly and without the first winding assembly during a failure of the first winding assembly and during a low power operation mode.
20. The aircraft of claim 19, wherein the first winding assembly has an axial width that is different than an axial width of the second winding assembly.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
(2)
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DETAILED DESCRIPTION
(9) Reference will now be made in detail to present embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the invention.
(10) As used herein, the terms first, second, and third may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components.
(11) The terms forward and aft refer to relative positions within a gas turbine engine or vehicle, and refer to the normal operational attitude of the gas turbine engine or vehicle. For example, with regard to a gas turbine engine, forward refers to a position closer to an engine inlet and aft refers to a position closer to an engine nozzle or exhaust.
(12) The terms upstream and downstream refer to the relative direction with respect to a flow in a pathway. For example, with respect to a fluid flow, upstream refers to the direction from which the fluid flows, and downstream refers to the direction to which the fluid flows. However, the terms upstream and downstream as used herein may also refer to a flow of electricity.
(13) The singular forms a, an, and the include plural references unless the context clearly dictates otherwise.
(14) Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as about, approximately, and substantially, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a ten percent margin.
(15) Here and throughout the specification and claims, range limitations are combined and interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.
(16) Referring now to the drawings, wherein identical numerals indicate the same elements throughout the figures,
(17) Each of the wings 20, 22 for the exemplary embodiment depicted includes one or more leading edge flaps 28 and one or more trailing edge flaps 30. The aircraft 10 further includes a vertical stabilizer 32 having a rudder flap (not shown) for yaw control, and a pair of horizontal stabilizers 34, each having an elevator flap 36 for pitch control. The fuselage 12 additionally includes an outer surface or skin 38. It should be appreciated however, that in other exemplary embodiments of the present disclosure, the aircraft 10 may additionally or alternatively include any other suitable configuration. For example, in other embodiments, the aircraft 10 may include any other configuration of stabilizer.
(18) Referring now also to
(19) Referring particularly to
(20) As shown in
(21) The exemplary turbomachine 102 depicted generally includes a substantially tubular outer casing 106 that defines an annular inlet 108. The outer casing 106 encases, in serial flow relationship, a compressor section including a booster or low pressure (LP) compressor 110 and a high pressure (HP) compressor 112; a combustion section 114; a turbine section including a first, low pressure (LP) turbine 118 and a second, high pressure (HP) turbine 116; and a jet exhaust nozzle section 120.
(22) The exemplary turbomachine 102 of the turbofan 100 additionally includes one or more shafts rotatable with at least a portion of the turbine section and, for the embodiment depicted, at least a portion of the compressor section. More particularly, for the embodiment depicted, the turbofan 100 includes a high pressure (HP) shaft or spool 122, which drivingly connects the HP turbine 116 to the HP compressor 112. Additionally, the exemplary turbofan 100 includes a low pressure (LP) shaft or spool 124, which drivingly connects the LP turbine 118 to the LP compressor 110.
(23) Further, the exemplary fan 104 depicted is configured as a variable pitch fan having a plurality of fan blades 128 coupled to a disk 130 in a spaced apart manner. The fan blades 128 extend outwardly from disk 130 generally along the radial direction R1. Each fan blade 128 is rotatable relative to the disk 130 about a respective pitch axis P1 by virtue of the fan blades 128 being operatively coupled to a suitable actuation member 132 configured to collectively vary the pitch of the fan blades 128. The fan 104 is mechanically coupled to the LP shaft 124, such that the fan 104 is mechanically driven by the first, LP turbine 118. More particularly, the fan 104, including the fan blades 128, disk 130, and actuation member 132, is mechanically coupled to the LP shaft 124 through a power gearbox 134, and is rotatable about the longitudinal axis 101 by the LP shaft 124 across the power gear box 134. The power gear box 134 includes a plurality of gears for stepping down the rotational speed of the LP shaft 124 to a more efficient rotational fan speed. Accordingly, the fan 104 is powered by an LP system (including the LP turbine 118) of the turbomachine 102.
(24) Referring still to the exemplary embodiment of
(25) Referring still to
(26) It should be appreciated, however, that in other exemplary embodiments, the electric generator 56 may instead be positioned at any other suitable location within the turbomachine 102 or elsewhere, and may be, e.g., powered in any other suitable manner. For example, the electric generator 56 may be, in other embodiments, mounted coaxially with the LP shaft 124 within the turbine section, or alternatively may be offset from the LP shaft 124 and driven through a suitable gear train. Additionally, or alternatively, in other exemplary embodiments, the electric generator 56 may instead be powered by the HP system, i.e., by the HP turbine 116 through the HP shaft 122, or by both the LP system (e.g., the LP shaft 124) and the HP system (e.g., the HP shaft 122) via a dual drive system.
(27) It should further be appreciated that the exemplary turbofan engine 100 depicted in
(28) Referring still to
(29) Additionally, the propulsion system 50 depicted further includes one or more energy storage devices 55 (such as one or more batteries or other electrical energy storage devices) electrically connected to the electrical power bus 58 for, e.g., providing electrical power to the second propulsor assembly 54 and/or receiving electrical power from the electric generator 56. Inclusion of the one or more energy storage devices 55 may provide performance gains, and may increase a propulsion capability of the propulsion system 50 during, e.g., transient operations. More specifically, the propulsion system 50 including one or more energy storage devices 55 may be capable of responding more rapidly to speed change demands.
(30) Referring now particularly to
(31) Referring still to the exemplary embodiment of
(32) The fan 204 includes a plurality of fan blades 208 and a fan shaft 210. The plurality of fan blades 208 are attached to/rotatable with the fan shaft 210 and spaced generally along a circumferential direction of the electric fan 200 (not shown). In certain exemplary embodiments, the plurality of fan blades 208 may be attached in a fixed manner to the fan shaft 210, or alternatively, the plurality of fan blades 208 may be rotatable relative to the fan shaft 210, such as in the embodiment depicted. For example, the plurality of fan blades 208 each define a respective pitch axis P2, and for the embodiment depicted are attached to the fan shaft 210 such that a pitch of each of the plurality of fan blades 208 may be changed, e.g., in unison, by a pitch change mechanism 211. Changing the pitch of the plurality of fan blades 208 may increase an efficiency of the second propulsor assembly 54 and/or may allow the second propulsor assembly 54 to achieve a desired thrust profile. With such an exemplary embodiment, the fan 204 may be referred to as a variable pitch fan.
(33) Moreover, for the embodiment depicted, the electric fan 200 depicted additionally includes a fan casing or outer nacelle 212, attached to a core 214 of the electric fan 200 through one or more struts or outlet guide vanes 216. For the embodiment depicted, the outer nacelle 212 substantially completely surrounds the fan 204, and particularly the plurality of fan blades 208. Accordingly, for the embodiment depicted, the electric fan 200 may be referred to as a ducted electric fan.
(34) Referring still particularly to
(35) As briefly noted above, the electric power source (i.e., the electric generator 56 and the first propulsor assembly 52 for the embodiment depicted) is electrically connected with the electric propulsion assembly (i.e., the electric motor 206 and the fan 204 of the electric fan 200 for the embodiment depicted) for providing electrical power to the electric propulsion assembly. More particularly, the electric motor 206 of the electric fan 200 is in electrical communication with the electric generator 56 through the electrical power bus 58, and more particularly through the one or more electrical cables or lines 60 extending therebetween.
(36) A propulsion system in accordance with one or more of the above embodiments may be referred to as a gas-electric, or hybrid, propulsion system, given that a first propulsor assembly is configured as a turbofan engine mounted to a first side of an aircraft and a second propulsor assembly is configured as an electrically driven fan mounted to a second side of the aircraft.
(37) It should be appreciated, however, that in other exemplary embodiments the exemplary propulsion system may have any other suitable configuration, and further, may be integrated into an aircraft 10 in any other suitable manner. For example, in other exemplary embodiments, the propulsion system may include a plurality of electric fans. One or more of these electric fans may be mounted to the wings, of the stabilizers, or to the fuselage, e.g., at an aft end of the aircraft. Other embodiments are contemplated as well.
(38) Referring now to
(39) As is depicted, the electric machine 300 generally defines a longitudinal centerline axis 302, a radial direction R3 relative to the longitudinal centerline axis 302, and a circumferential direction C3 extending about the longitudinal centerline axis 302 (see, e.g.,
(40) The rotor 304 and stator 306 of the electric machine 300 are enclosed within a housing 308. Additionally, for the embodiment depicted the rotor 304 is rotatably mounted within the housing 308 using a plurality of bearing assemblies 310. The plurality of bearing assemblies 310 may include, e.g., roller bearings, ball bearings, or any other suitable type of bearings. As is also shown, for the embodiment depicted the rotor 304 is formed integrally with a driveshaft 312 extending outward from the housing 308 of the electric machine 300. The driveshaft 312 may be coupled to, e.g., a propulsor when utilized as an electric motor, or an aeronautical combustion engine when utilized as an electric generator.
(41) It will be appreciated that for the embodiment depicted the rotor 304 is configured as a permanent magnet rotor including a plurality of permanent magnets 314. More specifically, the rotor 304 is configured as a surface permanent magnet rotor, with the plurality of permanent magnets 314 positioned on a radially outer surface 316 of the rotor 304. It should be appreciated, however, that in other exemplary embodiments the rotor 304 may instead include interior permanent magnets 314 (i.e., permanent magnets recessed from the radially outer surface 316 of the rotor 304). Additionally, or alternatively, in other embodiments, the rotor 304 may utilize electromagnets.
(42) As is also depicted, the stator 306 of the electric machine 300 further includes a plurality of winding assemblies 318. The plurality winding assemblies 318 are spaced along the longitudinal centerline axis 302 of the electric machine 300, with each winding assembly 318 operable with the rotor 304 independently of an adjacent winding assembly 318 during operation of the electric machine 300. For example, in certain embodiments, the stator 306 may include between two winding assemblies 318 and up to, e.g., about thirty winding assemblies 318. For example, in certain exemplary embodiments, the stator 306 may include at least three winding assemblies 318. More specifically, for the embodiment depicted, the stator 306 includes a first winding assembly 318A, a second winding assembly 318B, and a third winding assembly 318C spaced along the longitudinal centerline axis 302 of the electric machine 300.
(43) Referring particularly to
(44) Additionally, referring now particularly to
(45) It should be appreciated, however, that in other exemplary embodiments, the propulsion system 300 may have any other suitable configuration. For example, in other exemplary embodiments, the propulsion system 300 may be configured to generate direct current (DC) electrical power or alternating current (AC) electrical power (e.g., such as two-phase electrical power or three-phase electrical power). Additionally, or alternatively, the propulsion system 300 may be configured as a synchronous electric machine or as an asynchronous electric machine, and further may be a permanent magnet electric machine (as shown) or an electromagnetic electric machine.
(46) Referring now to
(47) Additionally, the propulsion system 350 of
(48) In addition, for the embodiment of
(49) With such a configuration, the electric machine 300 may generally operate as a plurality of separate electric machines 300 utilizing a common housing 308, rotor 304, etc. Accordingly, such a configuration may provide for an additional layer of redundancy, without the added weight and/or cost of including multiple, separate electric machines 300.
(50) It should be appreciated, however, that in other exemplary embodiments, the propulsion system 350 may have any other suitable configuration. For example, in other exemplary embodiments, the electric generator 356 may additionally, or alternatively, be configured in accordance with an exemplary embodiment of the present disclosure to include a stator 306 having a plurality of winding assemblies 318. Further, the propulsion system 350 may have any suitable configuration, as may the electric power bus 364.
(51) Additionally, in still other embodiments, the electric power bus 364 may be electrically connected to one or more of the electric machines 300 in any other suitable manner. For example, referring now to
(52) For example, the exemplary propulsion system 350 of
(53) However, for the embodiment depicted, one or more of the plurality of winding assemblies 318A, 318B, 318C are selectively in electrical communication with the electric power bus 364. More specifically, for the embodiment of
(54) It will be appreciated that such a configuration may allow for selective operation of one or more winding assemblies 318 of the electric machine 300, e.g., during a failure of one of the winding assemblies 318, or during an operation mode that uses less electrical power than the electric machine 300 generates or needs. Accordingly, in the latter situation, a temperature of the electric machine 300 may be reduced during operation modes requiring less electrical power.
(55) Further, it will be appreciated that although the exemplary electric machine is discussed in the context of a propulsion system, and more specifically an aircraft propulsion system, in other embodiments, the electric machine may be utilized for any other suitable purpose. For example, in other embodiments, the electric machine may be an electric motor (or generator) in any other suitable vehicle, such as an automobile, aeronautical vehicle, etc. Further, still, in other embodiments, the electric machine may be utilized in other fields, such as industrial or other fields.
(56) This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.