Embedded electric machine
11473441 · 2022-10-18
Assignee
Inventors
- Gert Johannes van der Merwe (Lebanon, OH, US)
- Daniel Alan Niergarth (Cincinnati, OH, US)
- Peter David Toot (Mason, OH, US)
Cpc classification
F01D5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D41/069
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2220/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/40311
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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
F04D19/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C7/36
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H1/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C3/113
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D15/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/4023
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01D15/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D15/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D19/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C7/36
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A gas turbine engine includes a compressor section and a turbine section. A first spool is rotatable with a first turbine of the turbine section and a first compressor of the compressor section. Additionally, a second spool is rotatable with a second turbine of the turbine section and a second compressor of the compressor section. An electric machine is positioned at least partially inward of the core air flowpath of the gas turbine engine along a radial direction of the gas turbine engine. Additionally, the exemplary gas turbine engine includes a gear assembly mechanically coupled to both the first spool and the second spool, such that the first and second spools may each drive the electric machine.
Claims
1. A gas turbine engine defining a radial direction and an axial direction, the gas turbine engine comprising: a compressor section comprising a first compressor and a second compressor; a turbine section comprising a first turbine and a second turbine, the compressor section and the turbine section together defining at least in part a core air flowpath; a first spool rotatable with the first turbine and the first compressor; a second spool rotatable with the second turbine and the second compressor; an electric machine comprising a rotor, the rotor being positioned at least partially inward of the second turbine along the radial direction, wherein the rotor and the second turbine at least partially overlap in the axial direction; and a gear assembly mechanically coupling the first spool and second spool to the electric machine for driving the electric machine.
2. The gas turbine engine of claim 1, wherein the gear assembly is an epicyclic gear assembly.
3. The gas turbine engine of claim 2, wherein the epicyclic gear assembly is a planetary gear assembly comprising a ring gear attached to the first spool, one or more planet gears attached to the second spool, and a sun gear attached to the electric machine.
4. The gas turbine engine of claim 3, wherein the one or more planet gears are configured as compound gears.
5. The gas turbine engine of claim 3, wherein the rotor is attached to a rotor shaft, and wherein the rotor shaft is attached to the sun gear.
6. The gas turbine engine of claim 1, further comprising: a turbine frame, wherein the second spool is supported at least partially by the turbine frame through a bearing.
7. The gas turbine engine of claim 6, wherein the second spool is configured for rotating in a first direction when operating, and wherein the gas turbine engine further comprises: a one-way clutch positioned between and contacting the second spool and the turbine frame such that the turbine frame, through the one-way clutch, prevents the second spool from rotating in a direction opposite the first direction.
8. The gas turbine engine of claim 7, wherein the one-way clutch is a sprag clutch.
9. The gas turbine engine of claim 1, wherein an effective turn-down ratio for the electric machine is less than 1.4:1.
10. The gas turbine engine of claim 1, wherein the first spool is a high pressure spool, and wherein the second spool is a low pressure spool.
11. The gas turbine engine of claim 1, wherein the electric machine is mounted at least partially aft of the turbine section along the axial direction.
12. The gas turbine engine of claim 1, wherein the electric machine is an electric generator.
13. The gas turbine engine of claim 1, wherein the electric machine is mounted coaxially with the first spool and coaxially with the second spool.
14. The gas turbine engine of claim 1, further comprising: a turbine frame; and a secondary electric machine comprising a second rotor rotatable with the second spool and a stator attached to the turbine frame.
15. A gas turbine engine defining a radial direction and an axial direction, the gas turbine engine comprising: a turbine section comprising a first turbine and a second turbine, the turbine section defining at least in part a core air flowpath; a first spool rotatable with the first turbine; a second spool rotatable with the second turbine; an electric machine comprising a rotor, the rotor being positioned at least partially inward of the second turbine along the radial direction, wherein the rotor and the second turbine at least partially overlap in the axial direction; and an epicyclic gear assembly coupled to the first spool, the second spool, and the electric machine such that both the first spool and second spool are configured for driving the electric machine.
16. The gas turbine engine of claim 15, wherein the epicyclic gear assembly is a planetary gear assembly comprising a ring gear attached to the first spool, one or more planet gears attached to the second spool, and a sun gear attached to the electric machine.
17. The gas turbine engine of claim 16, wherein the one or more planet gears are configured as compound gears.
18. The gas turbine engine of claim 16, wherein the rotor is attached to a rotor shaft, and wherein the rotor shaft is attached to the sun gear.
19. The gas turbine engine of claim 15, wherein the second spool is configured for rotating in a first direction when operating, and wherein the gas turbine engine further comprises: a turbine frame; and a one-way clutch positioned between and contacting the second spool and the turbine frame such that the turbine frame, through the one-way clutch, prevents the second spool from rotating in a direction opposite the first direction.
20. The gas turbine engine of claim 15, wherein an effective turn-down ratio for the electric machine is less than 1.4:1.
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)
(3)
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DETAILED DESCRIPTION OF THE INVENTION
(8) 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. 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. The terms “forward” and “aft” refer to relative positions within a gas turbine engine, with forward referring to a position closer to an engine inlet and aft referring to a position closer to an engine nozzle or exhaust. The terms “upstream” and “downstream” refer to the relative direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the direction from which the fluid flows, and “downstream” refers to the direction to which the fluid flows.
(9) The present application is directed generally towards a gas turbine engine including a compressor section and a turbine section. A first spool is rotatable with a first turbine of the turbine section and a first compressor of the compressor section. Additionally, a second spool is rotatable with a second turbine of the turbine section and a second compressor of the compressor section. The exemplary gas turbine engine further includes an electric machine positioned at least partially inward of the core air flowpath of the gas turbine engine along a radial direction of the gas turbine engine. The electric machine may, in at least certain embodiments, be configured as an electric generator for providing electric power to, e.g., an aircraft with which the gas turbine engine is installed. Additionally, or alternatively, the electric machine may be configured for providing electric power to one or more electric propulsion devices of a propulsion system of the aircraft with which the gas turbine engine is installed.
(10) Further, the electric machine is coupled to both the first spool and the second spool of the gas turbine engine through a gear assembly, such that both the first and second spools may drive the electric machine. As will be explained in greater detail below, such a configuration may allow for a reduction in a turndown ratio of the electric machine, which may in turn allow for a reduction in a size and weight of the electric machine.
(11) Referring now to the drawings, wherein identical numerals indicate the same elements throughout the figures,
(12) The exemplary core turbine engine 104 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 second, booster or low pressure (LP) compressor 110 and a first, high pressure (HP) compressor 112; a combustion section 114; a turbine section including a first, high pressure (HP) turbine 116 and a second, low pressure (LP) turbine 118; and a jet exhaust nozzle section 120. The compressor section, combustion section 114, and turbine section together define a core air flowpath 121 extending from the annular inlet 108 through the LP compressor 110, HP compressor 112, combustion section 114, HP turbine section 116, LP turbine section 118 and jet nozzle exhaust section 120. A first, high pressure (HP) shaft or spool 122 drivingly connects the HP turbine 116 to the HP compressor 112. A second, low pressure (LP) shaft or spool 124 drivingly connects the LP turbine 118 to the LP compressor 110.
(13) For the embodiment depicted, the fan section 102 includes a variable pitch fan 126 having a plurality of fan blades 128 coupled to a disk 130 in a spaced apart manner. As depicted, the fan blades 128 extend outwardly from disk 130 generally along the radial direction R. Each fan blade 128 is rotatable relative to the disk 130 about a pitch axis P 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 in unison. The fan blades 128, disk 130, and actuation member 132 are together rotatable about the longitudinal axis 12 by LP shaft 124 across a 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.
(14) Referring still to the exemplary embodiment of
(15) Additionally, the exemplary turbofan 100 depicted includes an electric machine 146. Specifically, for the embodiment depicted, the electric machine 146 is configured as an electric generator co-axially positioned with the LP shaft 124 and the HP shaft 122. As used herein, “co-axially” refers to the axes being aligned. Although not depicted, but as will be described in detail below, the electric machine 146 is mechanically coupled to the HP spool 122 and the LP spool 124 through a gear assembly.
(16) It should be appreciated, however, that the exemplary turbofan engine 100 depicted in
(17) Referring now to
(18) As discussed above, the turbine section generally includes the HP turbine 116 and the LP turbine 118. The HP turbine 116 includes a plurality of rotor blades 148 rotatable with the HP spool 122, as well as a plurality of fixed stator vanes 150. Similarly, the LP turbine 118 includes a plurality of turbine rotor blades 148 rotatable with the LP spool 124 and a plurality of fixed stator vanes 150. Moreover, the gas turbine engine includes a turbine center frame 152 and a turbine rear frame 154, each providing support for the various rotating components of the gas turbine engine. Specifically, the HP spool 122 is supported by the turbine center frame 152 through a first bearing 156, and similarly, the LP spool 124 is supported by the turbine rear frame 154 through a second bearing 158. The first and second bearings 156, 158 are depicted schematically as roller bearings, however in other embodiments, the first and/or second bearings 156, 158 may instead be configured as any other suitable bearing, or suitable plurality of bearings, positioned at any suitable location.
(19) As is depicted, for the embodiment of
(20) Moreover, for the embodiment depicted, the electric machine 146 is configured as an electric generator, driven by both the HP spool 122 and the LP spool 124 during at least certain operations, as will be discussed in greater detail below. More specifically, for the embodiment depicted, the gas turbine engine additionally includes a gear assembly 164 mechanically coupling the HP spool 122 and the LP spool 124 to the electric machine 146, such that one or both of the HP spool 122 and the LP spool 124 may transfer power to the electric machine, e.g., via a rotor shaft (such as the exemplary rotor shaft 172 described below).
(21) Referring now also to
(22) Referring now specifically to
(23) Notably, with such a configuration, torque from both the HP spool 122 and the LP spool 124 may be transferred through the gear assembly 164 and the generator rotor shaft 172 to drive the electric machine 146. Such a configuration may also reduce a turndown ratio for the electric machine 146. The turndown ratio refers to a ratio of maximum speed to minimum speed of the electric machine 146 between idle and rated engine power. Referring now briefly to
(24) An exemplary electric machine rotational speed line 188 is also depicted in
(25) It should be appreciated, that inclusion of a gear assembly for driving an electric machine capable of reducing an effective turndown ratio of the electric machine may allow for an overall reduction in size of the electric machine. Specifically, electric machines are typically required to generate a baseline amount of electric power across a wide array of rotational speeds of the engine. For example, in certain embodiments, the electric machine may be required to provide a baseline power (e.g., 1 megawatt) at idle conditions as well as during cruise conditions. By reducing an effective turndown ratio for the electric machine, the electric machine may be designed to operate within a smaller window of rotational input speeds, such that designing the electric machine to create the baseline amount of electrical power at a lower end of the range of input speeds does not result in an electric machine as oversized or over-engineered as may otherwise be necessary. Such may result in a lighter and more cost-efficient electric machine.
(26) Referring again to
(27) It should be appreciated, however, that in other embodiments, any other suitable one-way clutch 190 may be utilized, and further, the one-way clutch 190 may be positioned at any other suitable location.
(28) Furthermore, referring now to
(29) For example, the exemplary gas turbine engine depicted in
(30) Additionally, an electric machine 146 is positioned at least partially within or aft of the turbine section, radially inward of a core air flowpath 121 defined at least in part by the turbine section. Further, for the embodiment depicted, a gear assembly 164 is provided mechanically coupling the HP spool 122 and the LP spool 124 to the electric machine 146 for driving the electric machine 146. As with the embodiment of
(31) Moreover, for the embodiment of
(32) Inclusion of the secondary electric machine 204 may allow for siphoning power out of the LP system of the gas turbine engine during certain operations of the gas turbine engine. For example, during idle conditions, wherein the gas turbine engine is designed to operate with a minimum HP spool speed, it may be desirable to reduce a speed of the LP system such that a fan of the gas turbine engine also rotates at a lower speed (see
(33) In addition, the secondary electric machine 204 may be utilized to further reduce the turndown ratio of the primary electric machine 146. For example, the secondary electric machine 204 may be utilized to power the LP spool 124 to adjust a speed ratio between the LP spool 124 and HP spool 122. Accordingly, the secondary electric machine 204 may be utilized to reduce the turndown ratio to approximately 1:1, which may allow for the primary electric machine 146 to be designed at a minimum size.
(34) 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.