Energy recovery modules, generator arrangements, and methods of recovering energy in generator arrangements

Patent metadata

Field	Value
Publication number	US-10876424-B2
Application number	US-201916383625-A
Country	US
Kind code	B2
Filing date	Apr 14, 2019
Priority date	Apr 14, 2019
Publication date	Dec 29, 2020
Grant date	Dec 29, 2020

Abstract

An energy recovery module includes a manifold, a permanent magnet generator arranged within the manifold, and a thermal electric generator. The thermal electric generator is arranged within the manifold and is electrically connected to the permanent magnet generator to provide electrical power to a load using energy recovered from an expanded decomposition or combustion products traversing the manifold. Generator arrangements, unmanned aerial vehicles, and methods of generating electric power are also described.

First claim

What is claimed is:

1. An energy recovery module, comprising:
a manifold;
a permanent magnet generator arranged within the manifold; and
a thermal electric generator arranged within the manifold, wherein the thermal electric generator is electrically connected to the permanent magnet generator to provide electrical power to an electrical load using energy recovered from an expanded decomposition or combustion product flow traversing the energy recovery module.

2. The energy recovery module as recited in claim 1 , further comprising a heat exchanger arranged within the manifold, wherein the heat exchanger is in thermal communication with the thermal electric generator.

3. The energy recovery module as recited in claim 2 , wherein the heat exchanger extends circumferentially about the permanent magnet generator.

4. The energy recovery module as recited in claim 2 , wherein the heat exchanger has a diffuser vane array extending circumferentially about the permanent magnet generator.

5. The energy recovery module as recited in claim 2 , wherein the manifold has a turbine nozzle vane array extending circumferentially about the permanent magnet generator.

6. The energy recovery module as recited in claim 1 , wherein the manifold has an expanded decomposition or combustion products inlet, an ambient air inlet, and an expanded decomposition or combustion products/ambient air outlet each in fluid communication with the thermal electric generator.

7. The energy recovery module as recited in claim 6 , wherein a cold side of the thermal electric generator fluidly couples the ambient air inlet with the expanded decomposition or combustion products/ambient air outlet.

8. The energy recovery module as recited in claim 6 , wherein a hot side of the thermal electric generator fluidly couples expanded decomposition or combustion product inlet with the expanded decomposition or combustion product/ambient air mixture outlet.

9. The energy recovery module as recited in claim 6 , wherein the manifold includes a union fluidly coupling the expanded decomposition or combustion product inlet and the ambient air inlet to the expanded decomposition or combustion product/ambient air mixture outlet.

10. The energy recovery module as recited in claim 1 , wherein the permanent magnet generator includes a permanent magnet supported for rotation relative to the thermal electric generator about a rotation axis and a stator winding fixed relative to the thermal electric generator.

11. The energy recovery module as recited in claim 10 , further comprising a radial turbine fixed relative to the permanent magnet recover energy from the expanded decomposition or combustion product flow traversing the energy recovery module.

12. The energy recovery module as recited in 10 , further comprising an impeller fixed relative to the permanent magnet to draw ambient air into the manifold to cool the expanded decomposition or combustion product flow traversing the energy recovery module.

13. A generator arrangement, comprising:
an energy recovery module as recited in claim 1 ;
a power module in fluid communication with the manifold; and
a fuel module in fluid communication the power module to provide flow of liquid fuel for generating electric power with the power module.

14. The generator arrangement as recited in claim 13 , wherein the power module includes a power converter, wherein the power converter is electrically connected to (a) the power module, (b) the permanent magnet generator, and (c) the thermal electric generator to provide electric power from both the power module and the energy recovery module to the electrical load.

15. The generator arrangement as recited in claim 13 , wherein the power module includes a microturbine in fluid communication with the energy recovery module to communicate the expanded decomposition or combustion products to the energy recovery module.

16. The generator arrangement as recited in claim 13 , wherein the power module comprises:
a gas generator in fluid communication with the fuel module;
a turbine in fluid communication with the gas generator;
an interconnect shaft fixed relative to the turbine; and
an alternator with one or more alternator permanent magnet and an alternator stator coil or winding operably associated with the turbine, wherein the one or more alternator permanent magnet is fixed relative to the interconnect shaft.

17. The generator arrangement as recited in claim 13 , wherein the fuel module comprises:
a fuel header in fluid communication with the power module through a turbine speed control valve;
a first fuel pressure vessel and a second fuel pressure vessel in fluid communication with the fuel header;
a compressed gas header in fluid communication with the first fuel pressure vessel and the second fuel pressure vessel; and
a compressed gas pressure vessel in fluid communication with the compressed gas header, and therethrough with the turbine speed control valve through fuel header and first fuel pressure vessel and the second fuel pressure vessel.

18. The generator arrangement as recited in claim 13 , further comprising:
a charge of liquid mono-propellant or fuel contained in the fuel module and in fluid communication with the energy recovery module; and
a charge of compressed gas contained in the fuel module and urging the charge of liquid mono-propellant or fuel fluidly toward the energy recovery module.

19. An unmanned aerial vehicle, comprising:
an energy recovery module as recited in claim 1 , wherein the energy recovery module is carried by the unmanned aerial vehicle;
a power module with a microturbine in fluid communication with the energy recovery module, wherein the power module is carried by the unmanned aerial vehicle; and
a fuel module in fluid communication with the power module and carried by the unmanned aerial vehicle, wherein the energy recovery module is electrically connected to an electrical load carried by the unmanned aerial vehicle.

20. A method of generating electric power, comprising:
receiving a flow of expanded decomposition or combustion products at a manifold of an energy recovery module;
generating electric power from the expanded decomposition or combustion products a thermal electric generator arranged within the manifold;
generating additional electric power from the expanded decomposition or combustion products using a permanent magnet generator arranged within the manifold;
cooling the expanded decomposition or combustion products during traverse of the expanded decomposition or combustion products through the manifold; and
quieting the expanded decomposition or combustion products during traverse of the expanded decomposition or combustion products through the manifold.

Assignees

• Hamilton Sundstrand Corp
• Hamilton Sunstrand Corp

Inventors

• Himmelmann Richard A

Classifications

• H02K11/05

  Rectifiers associated with casings, enclosures or brackets · CPC title

• F01D15/10 Primary

  Adaptations for driving, or combinations with, electric generators · CPC title

• B60L50/90 Primary

  using propulsion power supplied by specific means not covered by groups B60L50/10 - B60L50/50, e.g. by direct conversion of thermal nuclear energy into electricity · CPC title

• B64U10/16

  with five or more distinct rotor axes, e.g. octocopters · CPC title

• B64U50/34

  In-flight charging (photovoltaics B64U50/31) · CPC title