Patent Description:
Electromechanical actuation motors ("EMAs") used in aircraft engine environments are difficult to cool due to a lack of cooling airflow, high radiation rates of the surrounding <NUM>° C air, and use of airflow axial and/or perpendicular to the motor making existing fin designs insufficient. In existing engine actuation systems, cooling can be achieved by transferring heat to a fluid powering the actuator. However, in the case of electromechanical actuation, heat transfer to a fluid is often unavailable and cooling can impose a burden in terms of cost, weight, and system complexity. Existing cooling fin designs can prove inadequate in high radiation environments with low airflow velocities. <CIT> relates to a heat transfer feature on a stator. <CIT> relates to a fin assembly. <CIT> relates to a wind power generation device. <CIT> relates to a housing for enclosing electronics.

An electromechanical actuation motor is provided in claim <NUM> and includes a main housing, a series of stator windings, and a first circumferential row of fins. The series of stator windings is disposed inside of the main housing. The first circumferential row of fins is connected to and extends radially from an outer surface of the main housing. The main housing and the first circumferential row of fins are formed as a single piece of material via layer-by-layer additive manufacturing. Each fin of the first circumferential row of fins includes a first portion and a second portion. The first portion is integrally formed with and attached to the outer surface of the main housing at a first end of the first portion. The second potion is attached to and integrally formed with a second end of the first portion. The first portion intersects the second portion to form a T-shape.

A method of forming a housing of an electromechanical actuation motor is provided in claim <NUM> and includes building a first housing with a layer-by-layer additive manufacturing process. The first housing is built to include an outer surface with a plurality of fins extending radially outward from the outer surface. Each fin includes first and second portions. The first portion is integrally formed with and attached to the outer at a first end of the first portion. The second portion is attached to and is integrally formed with a second end of the first portion. The first portion intersects the second portion such that the first and second portions of each fin form a T shape.

While the above-identified figures set forth one or more embodiments of the present disclosure, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents embodiments by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope of the disclosure. The figures may not be drawn to scale, and applications and embodiments of the present disclosure may include features and components not specifically shown in the drawings.

This disclosure presents additively manufactured fins with a "T" shape that are additively manufactured with the motor housing. The "T" shape of the fins provides the benefits of guiding airflow next to the body of the EMA while maintaining a laminar boundary layer. The spacing among the "T" fins provides cooling functionality in both parallel and perpendicular orientations, while the top of the "T" fin creates a radiation shield to further manage transfer of thermal energy.

<FIG> is a cross-section view of actuating system <NUM> and shows sync ring <NUM>, first EMA <NUM>, second EMA <NUM>, and controller <NUM>. Actuating system <NUM> is a system for actuating variable vanes in an aircraft. In this non-limiting embodiment, actuation system includes sync ring <NUM>, first EMA <NUM>, second EMA <NUM>, and controller <NUM>. In other embodiments, additional control components such as sensors, actuators and other subsystems may be utilized with actuating system <NUM>. Sync ring <NUM> is a generally circular ring with geared elements. First EMA <NUM> and second EMA <NUM> are electromechanical actuation motors. Controller <NUM> is a device for receiving, processing, producing, and sending electrical signals.

In this non-limiting embodiment, actuating system <NUM> is disposed in an aircraft and is connected to a variable stator vane arrangement. Sync ring <NUM> is connected to the turbine stator vanes (not shown) of the aircraft. First EMA <NUM> and second EMA <NUM> are operably coupled to sync ring <NUM>. For example, geared elements from first EMA <NUM> and second EMA <NUM> can be engaged with the geared elements of sync ring <NUM>. First EMA <NUM> and second EMA <NUM> are electrically connected to controller <NUM> via a wired connection. Controller <NUM> is electrically connected to first EMA <NUM> and second EMA <NUM>. In one example, controller <NUM> can be in communication with a full authority digital engine control.

Actuating system <NUM> controls an angle of the stator vanes based on an amount of desired thrust for the aircraft. Sync ring <NUM> actuates in response to torque received by first EMA <NUM> and second EMA <NUM>. The torque received by first EMA <NUM> and second EMA <NUM> is then transferred by sync ring <NUM> to the stator vanes so as to change an angle of the stator vanes. First EMA <NUM> and second EMA <NUM> drive actuation of sync ring <NUM> in response to communications received from controller <NUM>. Controller <NUM> sends and receives electrical signals from first EMA <NUM> and second EMA <NUM> in order to control operation of first EMA <NUM> and second EMA <NUM>.

<FIG> is a perspective view of first EMA <NUM> and shows first housing portion <NUM> (with first fin set <NUM>), second housing portion <NUM> (with second fin set <NUM> that includes second proximal row <NUM> and second distal row <NUM>), third housing portion <NUM> (with third fin set <NUM> that includes third proximal row <NUM> and third distal row <NUM>), endcap <NUM>, and panel <NUM>.

First housing portion <NUM>, second housing portion <NUM>, and third housing portion <NUM> are axial portions of a housing of first EMA <NUM>. First fin set <NUM>, second fin set <NUM>, and third fin set <NUM> are sets of cooling fins. In this non-limiting embodiment, the fins of second fin set <NUM> and third fin set <NUM> include a T-shape. In the claimed embodiment, the fins of first fin set <NUM> also include a T-shape. Second proximal row <NUM>, second distal row <NUM>, third proximal row <NUM>, and third distal row <NUM> are axially spaced rows of cooling fins. Endcap <NUM> is a lid or cover. Panel <NUM> is a planar piece of solid material that is an internal a surface of the aircraft. In one non-limiting embodiment, panel <NUM> can be a surface of a gear box of the aircraft.

First housing portion <NUM> is axially adjacent to and integrally formed with second housing portion <NUM>. First fin set <NUM> is integrally formed with and located on first housing portion <NUM>. The fins of first fin set <NUM> are integrally grown with first housing portion <NUM> via layer-by-layer additive manufacturing. First fin set <NUM> extends circumferentially around first housing portion <NUM>. In this non-limiting embodiment, the fins of first fin set <NUM> are uniformly spaced in a circumferential direction with respect to first housing portion <NUM>. The fins of first fin set <NUM> include a rectangular polygon shape. In another example, the fins of first fin set <NUM> can include a T-shape cross-section configuration as is shown by the fins of second and third fin sets <NUM> and <NUM>.

Second housing portion <NUM> is axially adjacent to and integrally formed with first housing portion <NUM> and third housing portion <NUM>. Second fin set <NUM> is integrally formed with and located on second housing portion <NUM>. The fins of second fins set <NUM> are integrally grown with second housing portion <NUM> via layer-by-layer additive manufacturing. Second fin set <NUM> extends circumferentially around second housing portion <NUM>. Second proximal row <NUM> is disposed on second housing portion <NUM> in a position that is axially closer to panel <NUM> than second distal row <NUM>. Second distal row <NUM> is disposed on second housing portion <NUM> in a position that is axially further from panel <NUM> than second proximal row <NUM>.

Third housing portion <NUM> is axially adjacent to and integrally formed with second housing portion <NUM>. Third fin set <NUM> is integrally formed with and located on third housing portion <NUM>. The fins of third fin set <NUM> are integrally formed with third housing portion <NUM> via layer-by-layer additive manufacturing. Third fin set <NUM> extends circumferentially around third housing portion <NUM>. Third proximal row <NUM> is disposed on third housing portion <NUM> in a position that is axially closer to panel <NUM> than third distal row <NUM>. Third distal row <NUM> is disposed on third housing portion <NUM> in a position that is axially further from panel <NUM> than third proximal row <NUM>. Endcap <NUM> is attached or mounted onto an end of third housing portion <NUM> opposite from second housing portion <NUM>. Panel <NUM> is attached or mounted to an end of first housing portion <NUM>.

First housing portion <NUM> connects second housing portion <NUM> to panel <NUM>. As will be discussed with respect to <FIG>, first fin set <NUM>, second fin set <NUM>, and third fin set <NUM> of fins increases a surface area of first, second, and third housing portions <NUM>, <NUM>, and <NUM> so as to increase a rate of transfer of thermal energy from the fins of first fin set <NUM>, second fin set <NUM>, and third fin set <NUM> to a flow of air passing across the fins of first fin set <NUM>, second fin set <NUM>, and third fin set <NUM>. First fin set <NUM>, second fin set <NUM>, and third fin set <NUM> of fins also block and reduce the radiation impact of thermal energy from components surrounding first EMA <NUM> in the aircraft.

Second housing portion <NUM> provides structural support for first EMA <NUM> and connects third housing portion <NUM> with first housing portion <NUM>. In this non-limiting embodiment, second housing portion <NUM> houses and contains a permanent motor. Third housing portion <NUM> provides structural support for third fin set <NUM> of fins. In this non-limiting embodiment, third housing portion <NUM> houses and contains a resolver (e.g., rotary electrical transformer). Endcap <NUM> surrounds a distal end of first EMA <NUM>. Panel <NUM> acts as a mounting surface to which first housing portion <NUM> of first EMA <NUM> is mounted to.

<FIG> is a cross-section view of first EMA <NUM> taken along the plane <NUM>-<NUM> from <FIG> and shows second housing portion <NUM> (with outer surface <NUM>), second distal row <NUM> of fins <NUM> each with first portion <NUM> (including length L<NUM>) and second portion <NUM> (including length L<NUM>), stator windings <NUM>, channels <NUM>, gaps <NUM>, and axial centerline ACL. The description herein of second housing portion <NUM> and fins <NUM> can also be generalized to describe first and third housing portions <NUM> and <NUM> and their respective fins.

Outer surface <NUM> is a radially exterior surface of second housing portion <NUM>. Fins <NUM> are radially extending pieces of solid material. Fins <NUM> are built with layer-by-layer additive manufacturing along with second housing portion <NUM> and such that fins <NUM> and second housing portion <NUM> are a single piece of solid material. In this non-limiting embodiment, fins <NUM> (and second housing portion <NUM>) are built with a laser sintering or powder bed fusion type of additive manufacturing. A material of fins <NUM> and second housing portion <NUM> can include a metal such as aluminum. In one non-limiting embodiment, a quantity of fins <NUM> can be from <NUM> to <NUM>. In this non-limiting embodiment, first portion <NUM> and second portion <NUM> are elongate rectangles of solid material. In other embodiments, first portion <NUM> and/or second portion <NUM> can include a degree of curvature or other non-linear shapes.

Length L<NUM> is a length of first portion <NUM> taken along a radial direction of second housing portion <NUM> relative to axial centerline ACL. In this example, length L<NUM> can range from <NUM> inches to <NUM> inches (e.g., <NUM> centimeters to <NUM> centimeters). Length L<NUM> is a length of second portion <NUM> taken along the direction shown in <FIG>, which is in a direction perpendicular to the radial direction of second housing portion <NUM>. In this example, length L<NUM> can range from <NUM> inches to <NUM> inches (e.g., <NUM> centimeters to <NUM> centimeters). In one non-limiting embodiment, a ratio of length L<NUM> to length L<NUM> can be approximately <NUM>:<NUM>. Also in this example, a thickness or first portion <NUM> and/or second portions <NUM> can range from <NUM> inches to <NUM> inches (e.g., <NUM> centimeters to <NUM> centimeters). Stator windings <NUM> are stator windings of a permanent motor. Channels <NUM> are spaces or passages formed between adjacent first portions <NUM>. Gaps <NUM> are spaces or channels formed between adjacent second portions <NUM>. Axial centerline ACL is a centerline axis of second housing portion <NUM> and of first EMA <NUM>.

Outer surface <NUM> extends circumferentially around second housing portion <NUM>. Fins <NUM> are formed with and extend radially outward from outer surface <NUM> of second housing portion <NUM>. In this example, fins <NUM> are situated around second housing portion <NUM> with uniform spacing between fins <NUM>. In other examples, the spacing between fins can be non-uniform or variable around the circumference of second housing portion <NUM>. Also in this example, lengths L<NUM> and L<NUM> are shown as uniform across all fins <NUM>. In other examples, lengths L<NUM> and L<NUM> can be non-uniform or variable around the circumference of second housing portion <NUM>.

First portion <NUM> is directly connected to outer surface. In this non-limiting embodiment, first portion <NUM> of each of fins <NUM> extends in a radial direction relative to axial centerline ACL of second housing portion <NUM>. First portion <NUM> is connected to second portion <NUM> at a mid-point of second portion <NUM>. In this non-limiting embodiment, second portion <NUM> is perpendicular to first portion <NUM>. In other examples, second portion <NUM> can be set at a non-perpendicular angle (e.g., a non-<NUM>° angle) to first portion <NUM>. In yet another example, first portion <NUM> can connected to second portion <NUM> at a point of second portion <NUM> that is not a mid-point of second portion <NUM>. Each first portion <NUM> forms one of channels <NUM> with an adjacent first portion <NUM>.

Second portion <NUM> is integrally formed with and to a distal end of first portion <NUM>. Each second portion <NUM> forms a gap between an adjacent second portion <NUM>. Stator windings <NUM> are positioned inside of second housing portion <NUM> in a circular arrangement. Axial centerline ACL passes through a mid-point of second housing portion <NUM> (and of first and third housing portions <NUM> and <NUM>). In this non-limiting embodiment, a build direction of the layer-by-layer additive manufacturing process of second housing portion <NUM> with fins <NUM> is into or out of the page (e.g., parallel to axial centerline ACL) as shown in <FIG>. In such an example, because first and third housing portions <NUM> and <NUM> are integrally formed with second housing portion <NUM>, a build direction of first and third housing portions <NUM> and <NUM> is also is into or out of the page as shown in <FIG>.

Fins <NUM> provide additional surface area to second housing portion <NUM> across which a flow of cooling air passes and comes into contact thereby increasing a transfer rate of thermal energy from second housing portion <NUM> to the flow of cooling air. First portions <NUM> provide structural support for second portions <NUM>. First portions <NUM> also form lateral boundaries of channels <NUM> that contain and channel the flow of cooling air through channels <NUM>. Second portions <NUM>, in combination with first portions <NUM>, trap and confine airflow in channels <NUM> between adjacent first portions <NUM> and radially inward from second portions <NUM>. Second portions <NUM> also acts as a heat shield by blocking heat radiated from other aircraft components from reaching second housing portion <NUM>.

Stator windings <NUM> create a magnetic field to generate force in the form of rotation of a rotary element of first EMA <NUM>. Channels <NUM> provide passages through which cooling airflow can travel and be in contact with outer surface <NUM> of second housing potion <NUM>, with first portions <NUM>, and with second portions <NUM> so as to transfer thermal energy to the passing cooling air. Gaps <NUM> allow air to flow into channels <NUM>. While some of the cooling airflow may dissipate out and through gaps <NUM>, second portions <NUM> contain a large portion of the flow of cooling air passing through channels <NUM>.

In one example, first EMA <NUM> can be positioned in an environment such that a direction of cooling airflow is perpendicular to axial centerline ACL. In such an example, gaps <NUM> allow cooling airflow to enter into channels <NUM> with second portions <NUM> trapping a majority of the airflow in channels <NUM>. Second portions <NUM> also shield and deflect direct impingement of thermal energy onto second housing portion <NUM>. In another example, first EMA <NUM> can be positioned in an environment such that a direction of cooling airflow is parallel to axial centerline ACL. In such an example, cooling airflow can flow directly into channels <NUM> between fins <NUM>.

The T-shape of fins <NUM> acts to guide cooling airflow next to the body of first EMA <NUM> while also maintain a laminar boundary layer of airflow. With the T-shape of fins <NUM>, spacing among fins <NUM> enables fluid management capabilities in both parallel and perpendicular orientations to a direction of cooling airflow. Additionally, second portions <NUM> of fins <NUM> (e.g., the top of the T) creates a radiation shield which blocks impinging radiating heat from components in the vicinity of first EMA <NUM>.

An electromechanical actuation motor includes a main housing, a series of stator windings, and a first circumferential row of fins. The series of stator windings is disposed inside of the main housing. The first circumferential row of fins is connected to and extends radially from an outer surface of the main housing. The main housing and the first circumferential row of fins are formed as a single piece of material via layer-by-layer additive manufacturing. Each fin of the first circumferential row of fins includes a first portion and a second portion. The first portion is integrally formed with and attached to the outer surface of the main housing at a first end of the first portion. The second potion is attached to and integrally formed with a second end of the first portion. The first portion intersects the second portion to form a T-shape.

The electromechanical actuation motor of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components.

The first portion can be longer than the second portion.

The first and second portions of each fin can be linear.

A ratio of the length of the first portion to a length of the second portion can be approximately <NUM>:<NUM>.

A second housing can extend axially from and/or be integrally formed with the first housing, wherein the second housing can be co-axial with the first housing; and/or a resolver disposed inside of the second housing.

A second circumferential row of fins can be connected to and/or extend radially from the second housing.

A drive shaft can extend axially from the first housing along the centerline axis.

The first portion can extend radially outward from the first end of the first portion to the second end of the first portion, and/or the second portion can extends perpendicularly from the second end of the first portion.

The second portions of the row of fins can form an interrupted cylinder with gaps formed between circumferentially adjacent second portions.

A method of forming a housing of an electromechanical actuation motor includes building a first housing with a layer-by-layer additive manufacturing process. The first housing is built to include an outer surface with a plurality of fins extending radially outward from the outer surface. Each fin includes first and second portions. The first portion is integrally formed with and attached to the outer at a first end of the first portion. The second portion is attached to and is integrally formed with a second end of the first portion. The first portion intersects the second portion such that the first and second portions of each fin form a T shape.

The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations, steps and/or additional components.

A build direction of the layer-by-layer additive manufacturing process can be in an axial direction of the housing.

Each fin can be formed such that the first and second portions of each fin can be linear.

Each fin can be formed such that a ratio of the length of the first portion to a length of the second portion can be approximately <NUM>:<NUM>.

A second housing can be formed to extend axially from and/or integrally formed with the first housing, wherein the second housing can be co-axial with the first housing.

A second circumferential row of fins can be formed to connect to and/or extend radially from the second housing.

The first portion can extend radially outward from the first end of the first portion to the second end of the first portion, and/or the second portion can extend perpendicularly from the second end of the first portion.

An assembly for actuating a sync ring in an aircraft includes an electromechanical actuation motor and the sync ring. The electromechanical actuation motor is the electromechanical actuation motor is configured to actuate a portion of the sync ring and includes a first housing, a series of stator windings disposed inside of the first housing, and a drive shaft that is rotatably driven by the stator windings. The first housing includes first circumferential row of fins connected to and extending radially from an outer surface of the first housing. The first housing and the first circumferential row of fins are formed as a single piece of material via layer-by-layer additive manufacturing. Each fin of the first circumferential row of fins includes first and second portions. The first portion is integrally formed with and is attached to the outer surface of the first housing at a first end of the first portion. The second potion is attached to and is integrally formed with a second end of the first portion. The first portion is longer than the second portion and intersects the second portion such that the first and second portions of each fin form a T shape. The sync ring is operably connected to the drive shaft of the electromechanical actuation motor.

Claim 1:
An electromechanical actuation motor (<NUM>) comprising:
a first housing portion (<NUM>) defining an outer surface;
a first fin set (<NUM>) extending radially from the outer surface, the first fin set (<NUM>) arranged in a first circumferential row and uniformly spaced, wherein the first housing portion (<NUM>) and the first fin set (<NUM>) are formed as a single piece of material via layer-by-layer additive manufacturing, a plurality of stator windings disposed inside of the first housing (<NUM>);
wherein each fin of the first fin set (<NUM>) comprises:
a first portion integrally formed with and attached to the outer surface
at a first end of the first portion; and characterized by a second portion attached to and integrally formed with a second end of the first portion, and wherein;
the first portion intersects the second portion such that the first and second portions of each fin form a T-shape and
the second portions of the row of fins form an interrupted cylinder with gaps formed between circumferentially adjacent second portions; and
wherein:
the second portions of the first fin set are spaced to form a heat shield that blocks radiant heat from reaching the first housing portion; and
a ratio of the length of the first portion to a length of the second portion is approximately <NUM>:<NUM>.