Abstract:
An electric machine includes a stator having an outer circumference. Spaced apart first walls are arranged about the outer circumference and provide generally parallel first channels. A second wall adjoins the first wall and is arranged about the outer circumference providing a second channel in fluid communication with the first channels, thus, providing a tortuous fluid flow path about the circumference. The first and second channels have an inner surface. A structure is provided within at least one of the first and second channels. The structure has an outer surface spaced radially outward from the inner surface and at least partially defines the tortuous flow path between the outer and inner surfaces. The stator includes an end turn. An end cap extends axially and radially outward from the stator and provides an enclosure about the end turn in fluid communication with the exit associated with the flow path.
Abstract:
A rotor of an electric machine includes a rotor core, a plurality of permanent magnets located at the rotor core, and a rotor sleeve enclosing the rotor core and the plurality of permanent magnets. One or more sleeve cooling channels are positioned between a radially outer surface of the rotor core and a radially inner surface of the rotor sleeve and extend axially along a length of the rotor. One or more radial cooling channels extend radially outwardly from an interior of the rotor core to the one or more sleeve cooling channels. The one or more radial cooling channels are configured to convey a flow of cooling fluid from the interior of the rotor core to the one or more sleeve cooling channels.
Abstract:
A wedge for a wound rotor includes a wedge body. The wedge body has a first layer and one or more second layers interfused with one another to provide structural support and limit resistive heating of the wedge from current flow within the wedge body by windings spaced apart by the rotor wedge. Generator rotors and methods of making generator rotors are also described.
Abstract:
Disclosed is a rotor for a generator, having: a rotor body; rotor poles extending radially outward from the rotor body, wherein each rotor pole includes a pole body and opposing pole circumferential side surfaces that are spaced apart from each other in a circumferential direction about the rotor body; coil windings wound about the rotor poles to form a wire bundle against one of the pole circumferential side surfaces; and a wire separator, disposed within the wire bundle, that divides the coil windings within the wire bundle into subsets of wire bundles.
Abstract:
A thermal management includes an inductor, a housing in thermal communication with the inductor, the housing defining a wall, and a conductor. The conductor has greater thermal conductivity than the wall and is positioned within a groove and/or an aperture formed in the wall. The conductor is configured to conduct heat through the wall more efficiently than if the conductor were not present. A method of manufacturing a thermal management system includes forming a housing by additive manufacturing. The housing defines a wall having at least one of a groove and an aperture defined therein. The method includes positioning a conductor in at least one of the groove and the aperture. The conductor has a greater thermal conductivity than the wall. The method includes positioning an inductor into thermal communication with the housing.
Abstract:
A waste heat capture system that can be used with at least a gas turbine engine. The system includes: an air scoop connected to a first component, the air scoop configured to direct air from a first duct to an interior compartment of the first component; a second duct along an exterior of the first component; and a thermoelectric material connected to an interior surface of the first component. The interior compartment of the first component is on a first side of the thermoelectric material and the exterior of the first component is on a second side of the thermoelectric material. The first duct is configured to receive air having a first temperature range, and the second duct is configured to receive air having a second temperature range, wherein the second temperature range is an order of magnitude higher than the first temperature range.
Abstract:
An engine system includes an engine duct and a tail cone arranged radially inwardly of the engine duct. The tail cone has an outer surface and an inner surface. A generator housing is arranged in the tail cone. The generator housing includes an outer surface portion spaced from the inner surface of the tail cone. A generator is mounted in the generator housing. An air duct extends from the generator, through the generator housing, through the tail cone, and through the engine duct. The air duct includes an opening exposed to an air stream passing over the engine duct.
Abstract:
A heat exchanger includes a pair of opposed, spaced apart heat exchanger plates defining a heat exchanger volume therebetween having an inlet and opposed outlet. A plurality of heat exchanger ribs are included within the heat exchanger volume. Each rib defines a rib body spanning the heat exchanger volume. Each rib body includes a plurality of slits therethrough to define a flow path through the heat exchanger ribs from the inlet to the outlet of the heat exchanger volume. The ribs and slits can be formed using ultrasonic additive manufacturing (UAM), for example.
Abstract:
A cabin air compressor assembly includes a cabin air compressor, and a cabin air compressor motor operably connected to the cabin air compressor. The cabin air compressor motor includes a rotor and a stator having a plurality of end windings. A cabin air compressor housing includes at least one cooling airflow hole formed therein. A motor cooling flow is movable across a portion of the cabin air compressor motor to cool the stator and the end windings. A duct extends from the cabin air compressor housing to an adjacent end winding such that a cooling outlet flow provided via the at least one cooling air flow hole is arranged in fluid communication with the end winding.
Abstract:
A system can include a compressor outlet line configured to receive compressor outlet flow from a compressor, a bypass line in fluid communication with the compressor outlet line and a motor outlet line to divert a bypass flow of the compressor outlet flow. The system can include at least one pump in fluid communication between the bypass line and the motor outlet line such that the bypass flow at least partially drives the pump to pull cooling flow through a motor to cool the motor.