Honeywell International Inc.

Wisconsin Alumni Research Foundation

University System of Maryland

Bulent Sarlioglu

Colin E Huggett

Renato Amorim Torres

Thomas Merlin Jahns

Yingjie Li

Hang Dai

Evgeni Ganev

Dwayne Michael Benson

Kellan P Geck

William Warr

George T Woessner

F Patrick McCluskey

Gokhan Cakal

Ju Hyung Kim

Di Han

Gregory F Nellis

Leyue Zhang

Hao Ding

Woongkul Lee

Zhaoxi Yao

James Swanke

Dheeraj Bobba

The thermal management system for in-slot cooling of electric motors includes separating structures, either in the form of a scaffolding structure or a monolithic winding structure which is placed in between the adjacent winding turns to physically separate the winding turns to define coolant fluid passages for circulation of a coolant fluid in direct contact with the lateral surfaces of the winding turns. The scaffolding and monolithic winding structures are made from an electrically insulating material and are filled with a dielectric fluid that serves both the coolant and the electrical insulator between the winding turns. An end-winding organizer may be positioned at two end regions of each stator tooth to provide a curved surface for the winding turns to be held in tension throughout the 180° winding end turns and is formed with grooves to define the passage for the coolant flow to ensure that the flowing coolant reaches the surface of the innermost winding turns.

Thermal management system and method for in-slot cooling of electric motors

An electrical machine includes a rotor, a stator, and a winding mounted within a housing. The rotor includes a rotor core mounted to a shaft and a plurality of blades extending radially away from the rotor core. Each blade of the plurality of blades is curved axially along the rotor core. The stator includes a stator core and a plurality of teeth extending from the stator core toward the rotor core to define a plurality of slots between successive teeth. The winding is wound through at least two slots of the plurality of slots. The stator is mounted radially relative to the rotor. The housing includes a front wall, a back wall, and a radial sidewall mounted between the front wall and the back wall to define an enclosure. A radial inlet aperture wall is formed circumferentially through the radial sidewall to form an opening through the radial sidewall.

Electrical machine cooling with axial and radial inlets and outlets

A switching circuit includes a reverse-voltage-blocking (RB) commutation switch, a first inverter leg, and a second inverter leg. The first inverter leg includes a first dual-gate bidirectional (DGBD) and a second DGBD switch connected in series. The second inverter leg includes a third and a fourth DGBD switch connected in series. A pair of the first DGBD switch, the second DGBD switch, the third DGBD switch, and the fourth DGBD switch that are in different inverter legs of the first inverter leg and the second inverter leg are configured to switch between a first DGBD on-state and a second DGBD on-state when in an inverting operating mode. A current with a positive or a negative polarity is conducted when in the first DGBD on-state. When in the second DGBD on-state, a reverse voltage is blocked by and a current with a positive polarity is conducted through the respective DGBD switch.

Current source inverter using bidirectional switches with bidirectional power flow capability

Stator packages and electric machines, and methods for cooling same, are disclosed herein. In an example embodiment, an electric machine includes a rotor, and a stator package having one or more stator coils, stator core portions, and a heat exchanger. The stator core portions and heat exchanger are arranged successively along a central axis, with the heat exchanger being positioned between the stator core portions. Each of the stator coils is arranged to extend along/within the stator core portions and heat exchanger. The heat exchanger includes walls forming passageways configured so that coolant entering the heat exchanger via an inlet both flows circumferentially from the inlet to an outlet, and additionally flows in an undulating manner both radially inwardly and outwardly substantially in between outer and inner wall surfaces of the heat exchanger, such that the coolant cools the one or more stator coils and the stator core portions.

System and method for electric machine cooling

A switching circuit for a current source inverter includes a first inverter leg, a second inverter leg, and a controller. The first inverter leg includes a first reverse-voltage-blocking (RB) switch, a second RB switch, and a third RB switch that are connected in series between a first bus line and a second bus line. The second inverter leg includes a fourth RB switch, a fifth RB switch, and a sixth RB switch are connected in series between the first bus line and the second bus line. The controller is configured to control a switch between an on-state and an off-state for each RB switch. When in the on-state, a reverse voltage is blocked by a respective RB switch, and a current with a positive polarity is conducted through the respective RB switch. When in the off-state, a voltage and the current are blocked by the respective RB switch.

Balanced current-source inverter

A switching circuit includes a diode, a semiconductor switch, and a first bidirectional switch. The semiconductor switch is configured to conduct a first current from a second terminal to a third terminal of the semiconductor switch when a first on-state signal is sent to a first terminal of the semiconductor switch. An anode of the diode is connected to the second terminal of the semiconductor switch, and a cathode of the diode is connected to the third terminal of the semiconductor switch. The first bidirectional switch includes a first terminal, a second terminal connected to the anode of the diode, and a third terminal and is configured to conduct a second current from the second terminal to the third terminal or from the third terminal to the second terminal when a second on-state signal is sent to the first terminal of the first bidirectional switch.

Current source inverter with bi-directional switches

An electric machine includes a rotor, a stator, and a winding. The rotor includes a rotor core and blades extending from the rotor core. Each blade is curved in an axial direction along the rotor core and is simultaneously configured as a pole that carries a magnetic flux of the electrical machine and as an airfoil that compresses a gas when the rotor is rotated. The gas flows axially between successive blades of the blades. The stator includes a stator core and teeth extending from the stator core toward the blades. Slots are defined between successive teeth. The winding is wound through at least two slots. The stator is mounted radially relative to the rotor so that a gap separates the blades from an exterior face of the teeth that is axially aligned along the stator core to follow an axial edge of a blade of the blades.

Integrated rotor for an electrical machine and compressor

An electric machine includes a rotor, a first stator, and a second stator. The rotor includes a rotor core and a first and a second plurality of poles mounted to extend radially from the rotor core. The first stator and the second stator each include a stator core, a plurality of teeth mounted to extend from the stator core, and a plurality of permanent magnets mounted as first spokes within the plurality of teeth. The stators are mounted radially relative to a first side of the rotor and separated by a first air gap between the plurality of poles and the plurality of teeth. At least four windings are connected in series and wound about the plurality of teeth. A first flux linkage in a first pair of series connected windings is a mirror image of a second flux linkage in a second pair of series connected windings.

Dual stator, flux switching permanent magnet machine

An inverter includes a plurality of inverter legs that each includes first, second, and third switches. A first control line connected to the first switch receives a first control signal. A second control line connected to the second switch receives a second control signal. A third control line connected to the third switch receives the first control signal. The first, second, and third switches are connected sequentially in series. A first connector line is connected between the first switch and the second switch and to a first winding of an electric machine. A second connector line is connected between the second switch and the third switch and to a second winding of the electric machine. The second control signal is complementary to the first control signal.

Inverter for common mode voltage cancellation

An electric machine includes a rotor, a first and second stator, a first and second plurality of permanent magnets, a first and second winding, a third and fourth winding. The first stator and the second stator are mounted axially relative to the rotor. A first permanent magnet and a second permanent magnet of the first plurality of permanent magnets have opposite polarities. A first permanent magnet and a second permanent magnet of the second plurality of permanent magnets have opposite polarities. The first winding, the second winding, the third winding, and the fourth winding are connected in series. An absolute value of an angle offset between the first winding and the third winding and between closest poles of the first plurality of poles and the second plurality of poles is 180 electrical degrees.

Axial flux switching permanent magnet machine

Regenerated power from actuation loads of an aircraft may be returned to the distribution bus of the aircraft. In the past, actuators were either hydrostatic or pneumatic. With the furtherance of more electric architecture (MEA) aircraft, there has been an increase in electrical actuation modes. The power or current exchange between electrical buses and the electromechanical and electro-hydrostatic flight control actuators is bidirectional, resulting in a need to accommodate regenerative power. Conventional methods may use shunt regulation to dissipate regenerated power. These methods require additional cooling to reject the heat generated. This regenerated power is wasted as dissipated heat. The present invention, on the other hand, may dump the regenerated power back to a power sink, such as into ancillary electrical loads or to the starter/generator as mechanical (kinetic) energy. In the present invention, the energy may not be wasted nor may it generate excessive heat that needs to be dissipated.

Method and system for improving electrical load regeneration management of an aircraft

A modular electromechanical actuation system assembly is provided that includes an electronic control unit housing having a plurality of motor receptacles and a plurality of battery receptacles formed in an outer surface thereof. Each of the motor receptacles has an associated motor electrical interface, and each of the battery receptacles has an associated battery electrical interface. An electronic control unit is disposed within the electronic control unit housing and is electrically coupled to each of the motor electrical interfaces and each of the battery electrical interfaces. A plurality of motors are supported, one each, within one of the motor receptacles, and a plurality of batteries are supported, one each, within one of the battery receptacles.

Modular, harnessless electromechanical actuation system assembly

A method and system for improving peak power capability in an electrical system is disclosed. The system may include an auxiliary generator operated in conjunction with one or more main engine generators during the need for increased transient load demands. The system may include a main engine generator, an auxiliary generator, an inverter/converter controller (ICC) connected to respective generators, a semi-conductor power device connected between the ICCs, and a main bus between the semi-conductor power device and a load.

Method and system for improving peak power capability of an aircraft

A system and method of controlling the power factor for providing either unity, leading or lagging results for the sensorless control of synchronous machines. The system and method provides an estimated angle of the phase current Park vector and uses a floating synchronous reference frame that is shifted from the estimated angle of the phase current Park vector by an angle &#x3b2; to allow the active control and change of the power factor during operation for applications such as producing reluctance torque of a salient pole synchronous machine during Main Engine Start (MES), and field weakening for Environmental Control Systems (ECS) and MES applications.

Power factor control for floating frame controller for sensorless control of synchronous machines

A system and method is provided for generating DC power using a synchronous reluctance machine () or a salient-pole synchronous machine () and a power converter (). The present invention can be used to achieve power production for a synchronous reluctance machine (), or can be used to achieve partial production of power from a traditional salient-pole synchronous machine/starter () in the case where the salient-pole synchronous machine/starter has degenerated into a synchronous reluctance machine due to, for example, a loss of excitation. In a power generation system, a control system and method can include a power converter (), controlled by a voltage command and at least one of a measured DC link () voltage or DC link () current, for use with a synchronous reluctance machine armature winding (A) and a prime mover (), such that movement of the synchronous reluctance machine rotor of the synchronous reluctance machine can be used to produce at least partial DC power generation.

Growing community of inventors

Torrance, CA, United States of America

Bulent Sarlioglu