Adjustable variable frequency starter/generator system

• US 7,105,937 B2
• Filed: 07/14/2004
• Issued: 09/12/2006
• Est. Priority Date: 07/14/2004
• Status: Active Grant

• Current Assignee: Hamilton Sundstrand Corporation (Rtx Corporation)
• Original Assignee: Hamilton Sundstrand Corporation (Rtx Corporation)
• Inventors: Turner, Douglas J., Thomson, Scott M., Hoppe, Richard J.
• Primary Examiner(s): Schuberg, Darren
• Assistant Examiner(s): Cuevas, Pedro J.
• Application Number:
  US10/891,370
• Publication Number:
  US 20060012180A1
• Time in Patent Office: 790 Days
• Field of Search: 290/38.R, 475/88
• US Class Current: 290/38.00R
• CPC Class Codes: F02C 7/268 Starting drives for the rotor , acting directly on the rotor of the gas turbine to be started
• CPC Class Codes: F02C 7/275 Mechanical drives
• CPC Class Codes: F02C 7/32 Arrangement, mounting, or driving, of auxiliaries
• CPC Class Codes: F02N 11/04 the motors being associated with current generators
• CPC Class Codes: H02K 7/116 with gears

Abstract

A starter/generator system for a gas turbine engine used in aeronautical applications that couples a single dynamoelectric machine to the gas turbine engine through a torque converter in a starting mode, and then disengages the torque converter and engages the engine to the dynamoelectric machine through an adjustable speed transmission in a generating mode after the engine reaches self-sustaining speed, wherein the speed of the adjustable speed transmission is set to match the frequency of AC generated by the dynamoelectric machine with on-board electrical equipment requirements to suit flight conditions.

Claims

1. A starter/generator system for starting a gas turbine engine for aeronautical applications comprising:

an alternating current dynamoelectric machine;

a torque converter with an input shaft coupled to a drive shaft of the dynamoelectric machine;

a first rotation-speed selective coupling with an input shaft coupled to an output shaft of the torque converter and an output shaft coupled to a drive shaft of the engine, wherein the first coupling transfers power from its input shaft to its output shaft so long as the input shaft rotates at least as fast as the output shaft for coupling the dynamoelectric machine through the torque converter to the engine in a starting mode;

an adjustable speed transmission with an input shaft coupled to the drive shaft of the engine;

a second rotation-speed selective coupling with an input shaft coupled to an output shaft of the adjustable speed transmission and an output shaft coupled to the drive shaft of the dynamoelectric machine, wherein the second coupling transfers power from its input shaft to its output shaft so long as the input shaft rotates at least as fast as the output shaft for coupling the engine through the adjustable speed transmission in a generating mode;

a hydraulic fluid source for selectively filling the torque converter with hydraulic fluid to transfer rotational power from the dynamoelectric machine to the engine during the starting mode; and

a control unit for switching the dynamoelectric machine from a starting mode to a generating mode when the engine reaches a self-sustaining rotational speed, coupling the hydraulic source to the torque converter in the starting mode and adjusting the ratio of the adjustable speed transmission to change the frequency of power generated by the dynamoelectric machine in the generating mode.

2. The starter/generator system of claim 1, further comprising a solenoid two-way valve coupled between the hydraulic fluid source and the torque converter and operated by the control unit to couple the hydraulic fluid source to the torque converter in the starting mode.

3. The starter/generator system of claim 1, further comprising:

an alternating current power source coupled to the dynamoelectric machine by the control unit during the starting mode; and

an alternating current bus coupled to the dynamoelectric machine by the control unit during the generating mode.

4. The starter/generator system of claim 3, further comprising:

a flight control unit for determining the frequency of power required by electrical components attached to the alternating current bus according to flight conditions, comparing the required power frequency to the frequency of power generated by the dynamoelectric machine, and providing the control unit with a difference signal, wherein the control unit adjusts the ratio of the adjustable speed transmission in response to the difference signal to change the frequency of power generated by the dynamoelectric machine to the required frequency.

5. The starter/generator system of claim 1, wherein the adjustable frequency transmission comprises a servo-controlled constant speed drive.

6. The starter/generator system of claim 1, wherein the adjustable frequency transmission comprises a servo-controlled continuously variable transmission.

7. The starter/generator system of claim 6, wherein the continuously variable transmission is a belt-driven continuously variable transmission.

8. The starter/generator system of claim 6, wherein the continuously variable transmission is a chain-driven continuously variable transmission.

9. The starter/generator system of claim 6, wherein the continuously variable transmission is a toroidal continuously variable transmission.

10. The starter/generator system of claim 1, wherein the first and second rotation-speed selective couplings are overrunning clutches.

11. The starter/generator system of claim 1, wherein the hydraulic fluid source comprises an oil pump.

12. The starter/generator system of claim 1, further comprising a rotary position sensor for generating a rotary speed signal indicative of the rotary speed of the dynamoelectric machine;

and

a support motor coupled to the dynamoelectric machine for bringing the dynamoelectric machine up to a predetermined rotary speed;

wherein the control unit monitors the rotary speed signal and powers the support motor in the starting mode until the rotary speed signal indicates that the dynamoelectric machine has reached the predetermined rotary speed.

13. The starter/generator system of claim 1, further comprising a rotary position sensor for generating a rotary speed signal indicative of the rotary speed of the dynamoelectric machine;

and

a motor controller coupled to the dynamoelectric machine for bringing the dynamoelectric machine up to a predetermined rotary speed;

wherein the control unit monitors the rotary speed signal and powers the motor controller in the starting mode until the rotary speed signal indicates that the dynamoelectric machine has reached the predetermined rotary speed.

14. The starter/generator system of claim 1, further comprising an engine speed sensor for generating an engine speed signal indicative of the rotational speed of the engine;

wherein the control unit monitors the engine speed signal and switches the dynamoelectric machine from the starting mode to the generating mode when the engine speed signal indicates that the engine has reached the self-sustaining rotational speed.

15. A starter/generator system for starting a gas turbine engine for aeronautical applications comprising:

an alternating current dynamoelectric machine;

a torque converter with an input shaft coupled to a drive shaft of the dynamoelectric machine;

a first rotation-speed selective coupling with an input shaft coupled to an output shaft of the torque converter and an output shaft coupled to a drive shaft of the engine, wherein the first coupling transfers power from its input shaft to its output shaft so long as the input shaft rotates at least as fast as the output shaft for coupling the dynamoelectric machine through the torque converter to the engine in a starting mode;

an adjustable speed transmission with an input shaft coupled to the drive shaft of the engine;

a second rotation-speed selective coupling with an input shaft coupled to an output shaft of the adjustable speed transmission and an output shaft coupled to the drive shaft of the dynamoelectric machine, wherein the second coupling transfers power from its input shaft to its output shaft so long as the input shaft rotates at least as fast as the output shaft for coupling the engine through the adjustable speed transmission in a generating mode;

a hydraulic fluid source for selectively filling the torque converter with hydraulic fluid to transfer rotational power from the dynamoelectric machine to the engine during the starting mode;

a control unit for switching the dynamoelectric machine from a starting mode to a generating mode when the engine reaches a self-sustaining rotational speed, coupling the hydraulic source to the torque converter in the starting mode and adjusting the ratio of the adjustable speed transmission to change the frequency of power generated by the dynamoelectric machine in the generating mode;

a solenoid two-way valve coupled between the hydraulic fluid source and the torque converter and operated by the control unit to couple the hydraulic fluid source to the torque converter in the starting mode;

an alternating current power source coupled to the dynamoelectric machine by the control unit during the starting mode; and

an alternating current bus coupled to the dynamoelectric machine by the control unit during the generating mode.

16. The starter/generator system of claim 15, further comprising:

a flight control unit for determining the frequency of power required by electrical components attached to the alternating current bus according to flight conditions, comparing the required power frequency to the frequency of power generated by the dynamoelectric machine, and providing the control unit with a difference signal, wherein the control unit adjusts the ratio of the adjustable speed transmission in response to the difference signal to change the frequency of power generated by the dynamoelectric machine to the required frequency.

17. The starter/generator system of claim 15, wherein the adjustable frequency transmission comprises a servo-controlled constant speed drive.

18. The starter/generator system of claim 15, wherein the adjustable frequency transmission comprises a servo-controlled continuously variable transmission.

19. The starter/generator system of claim 18, wherein the continuously variable transmission is a belt-driven continuously variable transmission.

20. The starter/generator system of claim 18, wherein the continuously variable transmission is a chain-driven continuously variable transmission.

21. The starter/generator system of claim 18, wherein the continuously variable transmission is a toroidal continuously variable transmission.

22. The starter/generator system of claim 15, wherein the first and second rotation-speed selective couplings are overrunning clutches.

23. The starter/generator system of claim 15, wherein the hydraulic fluid source comprises an oil pump.

24. The starter/generator system of claim 15, further comprising a rotary position sensor for generating a rotary speed signal indicative of the rotary speed of the dynamoelectric machine;

and

a support motor coupled to the dynamoelectric machine for bringing the dynamoelectric machine up to a predetermined rotary speed;

wherein the control unit monitors the rotary speed signal and powers the support motor in the starting mode until the rotary speed signal indicates that the dynamoelectric machine has reached the predetermined rotary speed.

25. The starter/generator system of claim 15, further comprising a rotary position sensor for generating a rotary speed signal indicative of the rotary speed of the dynamoelectric machine;

and

a motor controller coupled to the dynamoelectric machine for bringing the dynamoelectric machine up to a predetermined rotary speed;

wherein the control unit monitors the rotary speed signal and powers the motor controller in the starting mode until the rotary speed signal indicates that the dynamoelectric machine has reached the predetermined rotary speed.

26. The starter/generator system of claim 16, further comprising an engine speed sensor for generating an engine speed signal indicative of the rotational speed of the engine;

wherein the control unit monitors the engine speed signal and switches the dynamoelectric machine from the starting mode to the generating mode when the engine speed signal indicates that the engine has reached the self-sustaining rotational speed.

27. A starter/generator system for starting a gas turbine engine for aeronautical applications comprising:

an alternating current dynamoelectric machine;

a torque converter with an input shaft coupled to a drive shaft of the dynamoelectric machine;

a first rotation-speed selective coupling with an input shaft coupled to an output shaft of the torque converter and an output shaft coupled to a drive shaft of the engine, wherein the first coupling transfers power from its input shaft to its output shaft so long as the input shaft rotates at least as fast as the output shaft for coupling the dynamoelectric machine through the torque converter to the engine in a starting mode;

an adjustable speed transmission with an input shaft coupled to the drive shaft of the engine;

a second rotation-speed selective coupling with an input shaft coupled to an output shaft of the adjustable speed transmission and an output shaft coupled to the drive shaft of the dynamoelectric machine, wherein the second coupling transfers power from its input shaft to its output shaft so long as the input shaft rotates at least as fast as the output shaft for coupling the engine through the adjustable speed transmission in a generating mode;

a hydraulic fluid source for selectively filling the torque converter with hydraulic fluid to transfer rotational power from the dynamoelectric machine to the engine during the starting mode;

a control unit for switching the dynamoelectric machine from a starting mode to a generating mode when the engine reaches a self-sustaining rotational speed, coupling the hydraulic source to the torque converter in the starting mode and adjusting the ratio of the adjustable speed transmission to change the frequency of power generated by the dynamoelectric machine in the generating mode;

a solenoid two-way valve coupled between the hydraulic fluid source and the torque converter and operated by the control unit to couple the hydraulic fluid source to the torque converter in the starting mode;

an alternating current power source coupled to the dynamoelectric machine by the control unit during the starting mode;

an alternating current bus coupled to the dynamoelectric machine by the control unit during the generating mode; and

a flight control unit for determining the frequency of power required by electrical components attached to the alternating current bus according to flight conditions, comparing the required power frequency to the frequency of power generated by the dynamoelectric machine, and providing the control unit with a difference signal, wherein the control unit adjusts the ratio of the adjustable speed transmission in response to the difference signal to change the frequency of power generated by the dynamoelectric machine to the required frequency.

28. The starter/generator system of claim 27, wherein the adjustable frequency transmission comprises a servo-controlled constant speed drive.

29. The starter/generator system of claim 27, wherein the adjustable frequency transmission comprises a servo-controlled continuously variable transmission.

30. The starter/generator system of claim 29, wherein the continuously variable transmission is a belt-driven continuously variable transmission.

31. The starter/generator system of claim 29, wherein the continuously variable transmission is a chain-driven continuously variable transmission.

32. The starter/generator system of claim 29, wherein the continuously variable transmission is a toroidal continuously variable transmission.

33. The starter/generator system of claim 27, wherein the first and second rotation-speed selective couplings are overrunning clutches.

34. The starter/generator system of claim 27, wherein the hydraulic fluid source comprises an oil pump.

35. The starter/generator system of claim 27, further comprising a rotary position sensor for generating a rotary speed signal indicative of the rotary speed of the dynamoelectric machine;

and

a support motor coupled to the dynamoelectric machine for bringing the dynamoelectric machine up to a predetermined rotary speed;

wherein the control unit monitors the rotary speed signal and powers the support motor in the starting mode until the rotary speed signal indicates that the dynamoelectric machine has reached the predetermined rotary speed.

36. The starter/generator system of claim 27, further comprising a rotary position sensor for generating a rotary speed signal indicative of the rotary speed of the dynamoelectric machine;

and

a motor controller coupled to the dynamoelectric machine for bringing the dynamoelectric machine up to a predetermined rotary speed;

wherein the control unit monitors the rotary speed signal and powers the motor controller in the starting mode until the rotary speed signal indicates that the dynamoelectric machine has reached the predetermined rotary speed.

37. The starter/generator system of claim 27, further comprising an engine speed sensor for generating an engine speed signal indicative of the rotational speed of the engine;

wherein the control unit monitors the engine speed signal and switches the dynamoelectric machine from the starting mode to the generating mode when the engine speed signal indicates that the engine has reached the self-sustaining rotational speed.