Hamilton Sundstrand Corporation

Viktor Kilchyk

Brent J Merritt

Debabrata Pal

Christopher Simpson

Mark R Gurvich

Aiden Coutin

John H Paliulis

Jeremy Clavette

Mark Vignali

Ali Shakil

Ousmane Gaye

Jeffrey S Dearborn

John Giuliano

Dmytro M Voytovych

Nathan James Grathwohl

Mark G Vignali

An environmental control system (ECS) of an aircraft, having a heat exchanger; a compressor that receives a first airflow from a first air source, compresses the first airflow, and directs the first airflow to the heat exchanger; an axial flow turbine that receives a second airflow from a second air source, extracts energy from the second airflow, and directs the second airflow to the heat exchanger, wherein the heat exchanger directs the first airflow to a cabin of the aircraft and directs the second airflow overboard; and a shaft connected between the turbine and the compressor.

Powered turbo-expander combining centrifugal compressor and an axial flow turbine

In accordance with at least one aspect of this disclosure, a system includes an airflow line, a main compressor disposed in the airflow line configured to receive a ram air flow and supply a compressed air flow to the air flow line, and a motor operatively connected to drive the main compressor. An air cycle machine is disposed in the airflow line downstream of the main compressor configured to receive the compressed airflow and supply a cooled cabin airflow to an aircraft cabin. A cooling line tap disposed in the airflow line downstream of the air cycle machine configured to communicate a flow of cooling air to the motor from the airflow line to supply a portion of the cooled cabin airflow to one or more portions of the motor as motor cooling air via a first cooling airflow line.

Systems and methods for cooling motors

A hybrid airfoil bearing for a shaft is provided and includes airfoil bearing components and passive magnetic bearing components. The airfoil bearing components include a top foil immediately surrounding the shaft and additional components. The passive magnetic bearing components are integrated into the shaft and the additional components of the airfoil bearing components to remove a static load of the shaft on the top foil.

Hybrid airfoil and auxiliary magnetic bearings

A shroud reinforcement is provided for a shroud that is coaxial with and partially surrounds a rotor and that includes tubular and flange sections and a transition section axially interposed between the tubular and flange sections. The shroud reinforcement includes first fiber-reinforced polymer-matrix composite reinforcement elements with fibers extending along an axial dimension of the rotor and being disposed to reinforce the transition section and second fiber-reinforced polymer-matrix composite reinforcement elements with fibers extending along a circumferential dimension of the rotor and being disposed to reinforce the transition section.

Rotor containment structure

Apparatus and associated methods relate to control of flow of a fluid within a fluid conductor having fluid-impenetrable walls surrounding a lumen. The fluid impenetrable walls have a rigid portion, a thermally-deformable portion, and a thermal heater and/or cooler thermally coupled to the thermally-deformable portion. The thermally-deformable portion has a geometrical form that changes in response to changes in temperature of the thermally deformable portion. A flow controller receives a signal indicative of a desired flow rate and controls the thermal heater so as to cause the thermally-deformable portion to deform thereby controlling the fluid flow to the desired flow rate.

Controlling flow of a fluid using thermally deformable channel

An assembly includes a rotor shaft extending in an axial direction along a center axis of the assembly and a flange extending radially outward from the rotor shaft and circumferentially around the rotor shaft. An axial flux motor extends circumferentially around the rotor shaft. The axial flux motor includes an array of magnets, a stator support structure, and a plurality of coils. The array of magnets extending circumferentially around the rotor shaft. The stator support structure extends circumferentially around the rotor shaft and faces the flange. The plurality of coils extends circumferentially around the rotor shaft and faces the array of magnets in the axial direction. Each coil of the plurality of coils includes bearing windings and torque generating windings on the stator support structure. Both the bearing windings and the torque generating windings face the array of magnets in the axial direction.

Mixed flux motor with integrated journal and thrust bearings

In one aspect, a seal plate for a rotary machine includes a hub centered on a central axis and a disk portion extending radially outward from the hub. The hub and the disk portion include a plastic substrate and metal plating disposed on at least apportion of an outer surface of the plastic substrate. The plastic substrate has a matrix material and fibers embedded in the matrix material. The fibers have a first coefficient of thermal expansion. The metal plating has a second coefficient of thermal expansion. The fibers are selected such that a bulk coefficient of thermal expansion of the plastic substrate at the outer surface of the plastic substrate substantially matches the second coefficient of thermal expansion of the metal plating.

Metal plated additively manufactured plastic seal plates and their method of manufacturing

An air cycle machine includes a turbine section, a compressor section, an axial flux magnetic gear system electromechanically coupling the turbine section to the compressor section, and a stabilization system for at least one shaft of the air cycle machine. The axial flux magnetic gear system includes a stator, two rotors, a winding system, and a control module. Each rotor interacts with the stator such that the rotor rotates when the axial flux magnetic gear system is exposed to an electrical current. The winding system stabilizes the position of the rotors along their rotational axes. The control module is configured to supply the electrical current to at least one of the winding system, the stator, and the rotors to drive rotation of the rotors. The stabilization system stabilizes the position of the at least one shaft of the air cycle machine along the shaft's rotational axis.

Motor incorporating magnetic bearings

A system for cooling a cabin air compressor (CAC) motor includes a water separator which extracts water from airflow through a turbine and/or a fuel cell, and a CAC motor including cooling channels connected to an inlet and an outlet. The inlet of the CAC motor receives water from the water separator. The steam at the outlet of the CAC motor can be repurposed for warming utilities in an aircraft cabin, or for de-icing or increasing enthalpy of the turbine. The cooling water flow can be directed to the CAC motor in response to a predicted temperature of the CAC motor exceeding a threshold. The predicted temperature can be generated by feeding inputs including CAC motor input power measured by a power sensor, differential pressure measured by a pressure sensor, and a temperature at an air cooling inlet measured by a temperature sensor to a processor which generates a map model.

CAC motor auxiliary water cooling system

An additively manufactured component includes an outer shell, the outer shell enclosing a space therein. An inner lattice structure is in the space of the outer shell. Interspaces are formed in the inner lattice structure. A method of forming an additively manufactured component includes evacuating a chamber in which the additively manufactured component will be formed, and forming in the chamber layer by layer an outer shell enclosing a core. The core includes a lattice structure with interspaces formed in the lattice structure.

Additively manufactured turbomachinery components with designed atmosphere of an inner voided core for heat transfer control

An airfoil having: a composition gradient defining a first coefficient of thermal expansion and a second coefficient of thermal expansion that differs from the first coefficient of thermal expansion; and a thermoelectric junction operationally coupled to the composition gradient, wherein the composition gradient is formed of either of a plurality of dissimilar metals or of plastic with fillings or fibers.

Airfoil formed of thermally adaptive materials and a thermoelectric junction

An air cycle machine includes a turbine section, a compressor section, and an axial flux magnetic gear system electromechanically coupling the turbine section to the compressor section. The axial flux magnetic gear system includes a stator, two rotors, a winding system, and a control module. The stator includes stator pole sections and is oriented about a stator axis. Each rotor includes magnets arranged radially about a rotational axis which is aligned with the stator axis. Each rotor interacts with the stator such that the rotor rotates at a rotational speed when the axial flux magnetic gear system is exposed to an electrical current. The winding system stabilizes the position of the rotors along their rotational axes. The control module is configured to supply the electrical current to at least one of the winding system, the stator, and the rotors to drive rotation of the rotors.

Axial flux motor powered air cycle machine

A vehicle includes a first area conditioned by a first medium, a second area conditioned by a second medium, and an air management system. The air management system includes a source of third medium, an environmental control system fluidly coupled to the source of third medium and to the second area, and a closed loop vapor compression system having a refrigeration medium circulating therein. The vapor compression system is fluidly coupled to the first area, the second area, and the source of third medium. During normal operation, both a first flow of the third medium conditioned within the environmental control system and a second flow of the third medium are provided to the second area.

Hybrid environmental control system for split cooling

A flow conduit intended for use in a fouling environment includes at least one solid surface of a thermally adaptive material. The at least one solid surface is configured to undergo a shape change as a result of thermal cycling such the shape change dislodges unwanted material accumulated on the at least one solid surface during operation of the flow conduit in the fouling environment.

Thermally adaptive flow conduit

A radial diffuser includes an inlet section, outlet section, diffuser wall, and movable diffuser hub. The inlet section has a cylindrical shape and a circular cross section. The diffuser wall includes an inner surface defining a fluid flow path which is non-linear, and includes a convex curved section and a concave curved section. The convex curved section is adjacent to the inlet section and has a convex curvature. The concave curved section is adjacent to the outlet section and has a concave curvature. The movable diffuser hub is configured to move with respect to a central flow axis relative to the diffuser wall and can thereby alter a fluid flow through the radial diffuser.

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Lancaster, NY, United States of America

Viktor Kilchyk