Fault tolerant turbo-generator system

Patent metadata

Field	Value
Publication number	US-12095405-B2
Application number	US-202217651156-A
Country	US
Kind code	B2
Filing date	Feb 15, 2022
Priority date	Feb 15, 2022
Publication date	Sep 17, 2024
Grant date	Sep 17, 2024

Abstract

A turbo-generator system for generating propulsive electrical power for an aircraft includes an electric machine comprising: a rotor configured to be rotated by a gas-turbine of the turbo-generator system; a stator comprising: a first active section comprising first windings surrounding a first portion of the rotor, and a second active section comprising second windings surrounding a second portion of the rotor.

First claim

What is claimed is:

1. A turbo-generator system for generating propulsive electrical power for an aircraft, the turbo-generator system comprising:
an electric machine comprising:
a rotor configured to be rotated by a gas-turbine of the turbo-generator system;
a stator comprising:
a first active section comprising first windings surrounding a first portion of the rotor; and
a second active section comprising second windings surrounding a second portion of the rotor, wherein the first portion of the rotor is displaced from the second portion of the rotor along a longitudinal axis of the rotor;

a first plurality of rectifiers configured to convert alternating current (AC) electrical energy output by the first windings into first direct current (DC) electrical energy and output the first DC electrical energy onto a first DC electrical bus;
a second plurality of rectifiers configured to convert AC electrical energy output by the second windings into second DC electrical energy and output the second DC electrical energy onto a second DC electrical bus
a first position sensor configured to output a first indication of a rotational position of the rotor to controllers of the first plurality of rectifiers; and
a second position sensor configured to output a second indication of the rotational position of the rotor to controllers of the second plurality of rectifiers,
wherein the aircraft includes a plurality of electrical motors configured to propel the aircraft,
wherein a first sub-set of the plurality of electrical motors are configured to propel the aircraft using electrical energy sourced via the first DC electrical bus, and
wherein a second sub-set of the plurality of electrical motors are configured to propel the aircraft using electrical energy sourced via the second DC electrical bus.

2. The turbo-generator system of claim 1 , wherein:
the first windings comprise a first plurality of phase set windings that are respectively connected to the first plurality of rectifiers; and
the second windings comprise a second plurality of phase set windings that are respectively connected to the second plurality of rectifiers.

3. The turbo-generator system of claim 2 , wherein:
the first active section comprises a first plurality of slots,
each slot of the first plurality of slots is occupied by only a single phase set winding of the first plurality of phase set windings,
the second active section comprises a second plurality of slots, and
each slot of the second plurality of slots is occupied by only a single phase set winding of the second plurality of phase set windings.

4. The turbo-generator system of claim 1 , wherein the first active section operates as a first permanent magnet (PM) generator, and wherein the second active section operates as a second PM generator.

5. The turbo-generator system of claim 1 , wherein the turbo-generator system does not include a clutch configured to rotationally de-couple the rotor from the gas-turbine.

6. The turbo-generator system of claim 1 , further comprising a controller configured to selectively mitigate a fault in one of the first or second active sections.

7. The turbo-generator of claim 2 , wherein the first plurality of phase set windings comprises two phase set windings, and wherein the two phase set windings of the first plurality of phase set windings are electrically isolated from each other.

8. The turbo-generator system of claim 1 , wherein the first plurality of rectifiers and the second plurality of rectifiers each include two rectifiers, and wherein a failure of a single rectifier in either the first plurality of rectifiers or the second plurality of rectifiers results in a 25% power reduction.

9. The turbo-generator system of claim 3 , wherein a short circuit current in the first active section is of a similar magnitude to a nominal current in the first active section.

10. The turbo-generator system of claim 1 , wherein the first sub-set of the plurality of electrical motors are configured to propel the aircraft using only electrical energy sourced via the first DC electrical bus, and wherein the second sub-set of the plurality of electrical motors are configured to propel the aircraft using only electrical energy sourced via the second DC electrical bus.

11. An airframe comprising:
a turbo-generator system comprising:
an electric machine comprising:
a rotor configured to be rotated by a gas-turbine of the turbo-generator system;
a stator comprising:
a first active section comprising first windings surrounding a first portion of the rotor; and
a second active section comprising second windings surrounding a second portion of the rotor;

a first plurality of rectifiers configured to convert alternating current (AC) electrical energy output by the first active section into first direct current (DC) electrical energy; and
a second plurality of rectifiers configured to convert AC electrical energy output by the second active section into second DC electrical energy, wherein the first plurality of rectifiers output the first DC electrical energy onto a first DC bus, wherein the second plurality of rectifiers output the second DC electrical energy onto a second DC bus, and wherein the airframe further comprises:
a first propulsion module configured to propel the airframe using electrical energy sourced via the first DC bus but not electrical energy sourced via the second DC bus; and
a second propulsion module configured to propel the airframe using electrical energy sourced via the second DC bus but not electrical energy sourced via the first DC bus,
wherein the first portion of the rotor is displaced from the second portion of the rotor along a longitudinal axis of the rotor, and wherein the airframe further comprises:
a first position sensor configured to output a first indication of a rotational position of the rotor to controllers of the first plurality of rectifiers; and
a second position sensor configured to output a second indication of the rotational position of the rotor to controllers of the second plurality of rectifiers.

Assignees

• Rolls Royce Corp
• Rolls Royce Electrical Norway As
• Rolls Royce Singapore Pte Ltd

Inventors

• Loder David
• Trawick David Russell
• Husum Eirik Mathias
• Engevik Erlend
• Furuhaug Roar
• Gajanayake Chandana Jayampathi

Classifications

• B64D35/022

  of hybrid-electric type · CPC title

• B64D31/18

  for hybrid-electric power plants · CPC title

• B64D27/33

  Hybrid electric aircraft · CPC title

• H02P9/006 Primary

  Means for protecting the generator by using control (control effected upon generator excitation circuit to reduce harmful effects of overloads or transients H02P9/10) · CPC title

• H02K16/04 Primary

  Machines with one rotor and two stators · CPC title