COOPERATIVE SHAPE MEMORY ALLOY TORQUE TUBES FOR CONTINUOUS-ACTION TURNING MOTOR
20190048860 ยท 2019-02-14
Assignee
Inventors
Cpc classification
F05D2300/174
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C22C19/007
CHEMISTRY; METALLURGY
F05D2300/177
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H29/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2240/60
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/1431
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/172
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/11
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2220/323
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/142
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/1616
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03G7/065
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F03G7/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D15/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
An engine turning clock work motor including two shape memory alloy (SMA) torque tube actuators, ratcheting mechanisms, and gearing. The gearing communicates the SMA torque tube actuators with a common gear that applies torque to a shaft, so that while one torque tube is heated and applying torque, the other torque tube is relaxed (using a cooling mechanism). The ratchet prevents the relaxing torque tube from applying torque in the incorrect direction.
Claims
1. A motor (200), comprising: cooperatively connected (224) torque tubes (202a), (202b) each comprising a shape memory alloy (204), wherein the cooperatively connected torque tubes (202a), (202b) generate a continuous torque output (208c) when the torque tubes (202a), (202b) sequentially change shape (216) in response to heat (218).
2. The motor of claim 1, wherein the shape memory alloy (204) comprises Nickel and Titanium.
3. The motor of claim 1, wherein the shape memory alloy (204) comprises an alloy including at least two metals selected from nickel, titanium, zinc, copper, gold, palladium, platinum, and iron.
4. The motor (200) of claim 1, wherein the SMA (204) consists essentially of NiTiHf having an Hf content in a range of 10%-30%.
5. The motor of claim 1, wherein the torque tubes each have a length (L) in a range of 5-50 inches and a diameter (OD), (ID) in a range of 0.1-2 inches.
6. The motor of claim 1, wherein the shape memory alloy (204) comprises a composition and the torque tubes (202b), (202a) have dimensions (L), (OD), (ID), such that the torque tubes (202b), (202a) output at least 200 inch pounds of torque (208c) in response to the SMA changing temperature by 300 degrees Celsius.
7. The motor of claim 1, wherein: the cooperatively connected (224) torque tubes (202a), (202b) comprise a pair of the torque tubes (202a, 202b) connected to gearing (206), the gearing (206) transfers torque (208a), (208b) from each torque tube (202a, 202b) sequentially so as to generate the continuous torque output (208c), and the torque (208a), (208b) from each of the torque tubes (202a, 202b) is in the same direction (210).
8. The motor of claim 7, further comprising a heater (402) coupled to each of the torque tubes (202a, 202b), wherein each of the torque tubes (202a, 202b) change their shape (224) by untwisting (302) in response to the heat (218) applied by the heater (402) that transforms the SMA into an austenitic phase (308).
9. The motor of claim 8, wherein the heater (402) comprises a coil (404) of wire (406) about one end (408) of each of the torque tubes (202a, 202b), so as to provide the heat (226) through induction when a current (I) is passed through the wire (406).
10. The motor of claim 8, further comprising: an output shaft (220) connected to the gearing (206); a controller (1100) activating the heater (402) so as to sequentially heat (218) the torque tubes (202a, 202b), wherein: the gearing (206) transfers the torque (208a) from one of the torque tubes (202a) to the output shaft (220) when the other of the torque tubes (202b) is cooling (312), and the torque (208a) from each of torque tubes (202a, 202b) turns (400) the output shaft (220) in the same direction (210).
11. The motor of claim 10, further comprising a cooling system (604) coupled to each of the torque tubes (202a, 202b), wherein the torque tube (202a, 202b) that is cooling (312) twists in response to the cooling (312) from the cooling system (604) that transforms the shape memory alloy into a martensitic phase (306).
12. The motor of claim 10, further comprising a ratcheting mechanism (212) connected to the end (214) of each of the torque tubes (202a, 202b) so that each of the torque tubes (202a),(202b) untwist (302) continuously in a first direction (210) in response to the heat (310).
13. The motor of claim 1, wherein the torque tubes (202a), (202b) are each trained to output torque (208a), (208b) capable of turning (606) a rotor shaft (122) so as to reduce or prevent thermal bowing (B) of the rotor shaft (122) in a temperature gradient (T).
14. The motor of claim 13, wherein: the rotor shaft (122) has a longitudinal axis (128) and is disposed inside a casing (104, 106, 140); the casing (104, 106, 140) comprises trapped air (116) creating the temperature gradient (T) perpendicular to the longitudinal axis (128), and the torque (208c) turns (606) the rotor shaft (122) about the longitudinal axis (128).
15. The motor of claim 12, wherein the rotor shaft (122) is the rotor shaft in an aircraft gas turbine engine (138).
16. The motor of claim 13, wherein the motor (200) is attached to an aircraft engine gearbox 500.
17. a torque tube (202a), comprising: a shape memory alloy (204), wherein the torque tube (202a) is trained to output torque (208a) capable of turning (606) a rotor shaft (122) so as to reduce or prevent thermal bowing (B) of the rotor shaft (122) in a temperature gradient (T).
18. The torque tube of claim 1, wherein the SMA (204) consists essentially of NiTiHf having an Hf content in a range of 10%-30% and the torque tube (202a) has a length (L) in a range of 5-50 inches and a diameter (OD), (ID) in a range of 0.1-2 inches.
19. A motor (200), comprising: a pair of torque tubes (202a),(202b) each comprising a shape memory alloy (204), wherein the torque tubes (202a),(202b) are each trained to output torque (208a) when the shape memory alloy is heated into an austenitic phase (306); a ratcheting mechanism (212) connected to each of the torque tubes (202a),(202b) and allowing untwisting (304) of the torque tube (202a), (202b) in a first direction (210); and gearing (206) connected to the torque tubes (202a),(202b) wherein: the gearing (206) outputs the torque (208a) from each torque tube (202a, 202b) sequentially, the torque (208a) from each of the torque tubes (202a, 202b) is in the same direction (210).
20. The motor of claim 19, wherein the torque tubes (202a), (202b) are each trained to output torque (208a) capable of turning (606) a rotor shaft (122) so as to reduce or prevent thermal bowing (B) of the rotor shaft (122) in a temperature gradient (T).
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
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DESCRIPTION
[0028] In the following description, reference is made to the accompanying drawings which form a part hereof, and which is shown, by way of illustration, several embodiments. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present disclosure.
Technical Description
Example Apparatus
[0029]
[0030] In one or more embodiments, the cooperatively connected torque tubes (202a), (202b) generate the torque output (208c) that is continuous (e.g., without interruption in time) when the torque tubes (202a), (202b) sequentially change shape (216) in response to heat (218) and the torque output (208c) transitions from comprising the torque (208a) provided by one torque tube (202a) to comprising the torque (208b) provided the other torque tube (202b). The gearing (206) transfers the torque output (208c) to an output shaft (220) connected to the gearing (206).
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Example Installation
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[0039] When the output shaft (220) engages the transmission (130), the motor (200) drives or turns the rotor shaft (122), e.g., so as to reduce or prevent thermal bowing (B) of the rotor shaft (122) in a temperature gradient (T). In one or more embodiments, the transmission (130) comprises a clutch drivably coupling the output shaft (220) to the transmission shaft (130a).
Example Application
[0040]
[0041] When the motor (200) is activated, the gearing (206) outputs the torque (208c) to the transmission (130) via gearbox (500). The torque (208c) is transmitted to the rotor shaft (122) via the transmission (130) comprising a transmission shaft (130a) and gearing (130b), (130c) connecting the transmission shaft (130b) to the rotor shaft (122).
[0042] A controller (1100) activates the heater/heating system (602) so as to sequentially heat (218) the torque tubes (202a, 202b) and the gearing (206) transfers the torque (206a) from one of the torque tubes (202a) when the other of the torque tubes (202b) is cooled (using cooling system (604)). As described herein, the torque tube (202a), (202b) that is cooling (312) is disengaged from the transmission (130).
[0043] Thus, the torque (208a), (208b) from each of torque tubes (202a, 202b) turns (606) the rotor shaft (122) in one direction about the longitudinal axis (128) so as to reduce or prevent thermal bowing (B) of the rotor shaft (122) in a temperature gradient (T).
[0044] In various embodiments, the motor (200) turns (606) the rotor shaft (122) periodically (i.e. once every 10 minutes, 30 minutes, hour, etc.) over a period of time (e.g., 8 hours) to promote an even temperature profile in the rotor shaft 122. Rotation examples include the motor (200) turning or rotating the rotor shaft (122) a full revolution, a plurality of revolutions, a partial revolution, or in increments. In one example, the motor (200) drives the rotor shaft (122) with a speed and for a duration such that the probability of a compressor rub is less than e-8 per flight-hour (or less than 1 chance in 100 million per flight hour (1108 per flight hour))
[0045] Examples of the heater (602) include, but are not limited to, an energy harvester that transfers waste heat from the aircraft or aircraft engine (138) so as to heat the torque tubes (202a), (202b) into the austenitic phase. Examples of the cooler/cooling system (604) include, but are not limited to, a passive cooling system or a system that uses air cooling (e.g., using pressurized air).
Experimental results
[0046]
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[0050] The results presented herein demonstrate that SMA motors (200), (400) may replace conventional actuation systems such as DC motors.
Process Steps
[0051]
[0052] Block 1000 represents obtaining an untwisted torque tube (316) comprising or consisting essentially of, an SMA.
[0053] Examples of torque tube dimensions include, but are not limited to, a length L in a range of 5-50 inches and a diameter (OD or ID) in a range of 0.1-2 inches.
[0054] In one or more embodiments, the SMA comprises or consists essentially of nickel and titanium. In yet further embodiments, the SMA comprises, or consists essentially of, nickel, titanium, and hafnium (NiTiHf). In one example, the Hf content in the NiTiHf is in a range of 10%-50%. In another example, the Hf content in the NiTiHf is in a range of 15%-30%. In yet another example, the NiTiHf contains 50% Hf, 10%-25% Hf, with Ti making up the remainder.
[0055] SMA compositions consisting essentially of NiTi may be particularly suitable for use with heating systems (502) that harvest waste heat energy used to heat the SMA into the austenitic phase (thereby reducing power consumption). SMA compositions consisting essentially of NiTiHf may be particularly suitable for use with passive cooling systems (604) used to cool the SMA into the martensitic phase (SMA's consisting essentially of NiTi may require relatively more complex cooling systems for cooling (312) into the martensitic phase).
[0056] Block 1002 represents heating the torque tube (316) so that the SMA has an austenitic structure (306) and the torque tube is in an untwisted state (forming untwisted tube (318)). In one or more embodiments, the heating uses induction heating via a magnet wire and a high frequency, high current amplifier.
[0057] Block 1004 represents cooling the torque tube (318) so that the SMA transforms into a martensitic structure or phase (308). In one embodiment, the cooling is air cooling, e.g., using pressurized air.
[0058] Block 1006 represents twisting the torque tube (318) comprising the SMA having the martensitic structure, so as to form a twisted torque tube (320).
[0059] Block 1008 represents heating the twisted torque tube (320) so that the twisted torque tube untwists to the untwisted state (forming untwisted tube (318)). Steps (1000)-(1006) may be repeated as desired until the desired torque output (208a) is achieved, so as to form torque tubes (202a), (202b).
[0060] In one or more embodiments, the torque tube (202a), (202b) after the thermomechanical treatment of steps (1000)-(1006) is further characterized by an actuation modulus of 1.1 MPSI in the austenite phase (306) and 1.8 MPSI in the martensitic phase (308), as well as a two way shape memory effect (SME) of 3.6% (the material remembers its austenite shape. and with 2 way SME training, thermomechanical processing creates the memory of the stable martensite shape). Higher torque at a higher temperature is typically achieved using the NiTiHf torque tube as compared to a the torque tube consisting essentially of NiTi. The temperature range at which NiTi changes shape is between 50 C.-110 C. whereas the temperature range at which the NiTiHf changes shape depends on stoichiometry (NiTiHf with 20% Hf is changes shape at 125 C.-200 C.
[0061] In one or more embodiments, the untwisting of the torque tubes (202a), (202b) outputs torque (208a), (208b) capable of turning (606) a rotor shaft (122) so as to reduce or prevent thermal bowing (B) of the rotor shaft (122) in a temperature gradient (T). In yet further embodiments, the SMA comprises a composition and the torque tubes (202b), (202a) have dimensions, such that the torque tube (202a), (202b) outputs at least 200 inch pounds of torque (208a), (208b) in response to the torque tube (202a), (202b) changing in temperature by 300 degrees when heat (218) is applied.
[0062] In various examples, a 0.325 OD torque tube (202a) generates over 200 in-lbs of torque, a 2 OD torque tube (202a) generates over 35,000 in-lbs of torque, and a 1.5 OD torque tube (202a) generates 15,000 in-lbs of torque, and a 0.1 OD torque tube (202a) tube generates 15 in lbs torque.
[0063] Block 1010 represents attaching means (222) for preventing the relaxing torque tube (202a) (202b) from applying torque in the incorrect direction (e.g., when cooling (312) or heating (218)). In one or more examples, the means (222) comprises a ratcheting mechanism (212) attached to the torque tube as illustrated in
[0064] Block 1012 represents connecting a plurality (e.g., a pair) of the torque tubes (202a), (202b). In one or more embodiments, the connection (224) or means for connecting the torque tubes (202a), (202b) comprises a gear system (206) including e.g., sprag gears (206b)) cooperatively connecting the ends (226) of one or more of the torque tubes (202a), (202b). Various gearing ratios may be used for the gearing (206). In one embodiment, the output (208c) from the gearing (206) is geared at a 5:1 ratio.
[0065] Block 1014 represents housing the torque tubes and gear system in a housing (228), such as a line replaceable unit (LRU) system. In one or more embodiments, the housing (228) has a length (L) of 10.5 inches, a width (W) of 6 inches, and a height (H) of 4 inches.
[0066] Block 1016 represents the end result, an SMA turning motor (200). In one or more embodiments, the power requirement for heating each torque tube (202a), (202b) is 400 Watts for a half cycle and the motor (200) outputs 200 inch pounds of torque (208c) at 1 revolution per minute (RPM). In one example, the motor (200) has a weight of 2 lbs.
[0067] As a comparison, conventional engine turning motors weigh 25 lbs and output only 66 inch pounds of torque, and gearbox torque generators weigh 16 lbs and output 190 inch pounds of torque. Thus, SMA motors according to embodiments of the present invention output surprisingly and unexpectedly higher torque outputs while having the advantage of significantly lower weight. These properties are particularly advantageous for aircraft applications. These unique actuation capabilities of the SMA motor enable new capabilities and applications.
[0068] Moreover, the combination of SMA with ratcheting gears (212) overcomes any problems that may arise due to slow actuation of a single torque tube. In a paired scheme, continuous torque is provided (one tube relaxes/cools while the other tube is in use providing torque).
Processing Environment
[0069]
[0070] The computer 1102 comprises a processor 1104 (general purpose processor 1104A and special purpose processor 1104B) and a memory, such as random access memory (RAM) 1106. Generally, the computer 1102 operates under control of an operating system 1108 stored in the memory 1106, and interfaces with the user/other computers to accept inputs and commands (e.g., analog or digital signals) and to present results through an input/output (I/O) module 1110. The computer program application 1112 accesses and manipulates data stored in the memory 1106 of the computer 1102. The operating system 1108 and the computer program 1112 are comprised of instructions which, when read and executed by the computer 1102, cause the computer 1102 to perform the operations herein described. In one embodiment, instructions implementing the operating system 1108 and the computer program 1110 are tangibly embodied in the memory 1106, thereby making a computer program product or article of manufacture. As such, the terms article of manufacture, program storage device and computer program product as used herein are intended to encompass a computer program accessible from any computer readable device or media.
[0071] In one embodiment, computer 1102 comprises one or more field programmable gate arrays (FPGAs).
[0072] In one embodiment, an Electronic Engine Control (EEC) sending a digital request to the computer 1102 through I/O 1110 to activate/de-activate the heater (602) or cooler (604) in order to rotate the rotor shaft (122), thus controlling HP compressor 108 speeds.
[0073] In one embodiment, the I/O 1110 receives signal from an engine shut off switch after engine 200 shut down, thereby activating the motor (200) to turn the rotor soon/immediately after engine shut down so as to minimize aircraft departure delays caused by mitigating rotor shaft bow.
[0074] In another embodiment, the duration of rotation (606) is optimized by having the computer 1102 estimate the amount of bow (based on time since last engine shutdown) and calculate the required rotation duration to be implemented. Various instrumentation to monitor the bowing can include accelerometers already used for vibration monitoring or microwave-based gap measuring sensors.
[0075]
[0076] Those skilled in the art will recognize many modifications may be made to this configuration without departing from the scope of the present disclosure. For example, those skilled in the art will recognize that any combination of the above components, or any number of different components, peripherals, and other devices, may be used.
Conclusion
[0077] This concludes the description of the preferred embodiments of the present disclosure. The foregoing description of the preferred embodiment has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of rights be limited not by this detailed description, but rather by the claims appended hereto.