Patent ID: 12244204

In general, the same reference numbers will be used throughout the drawing(s) and accompanying written description to refer to the same or like parts. The figures are not to scale. Instead, the thickness of the layers or regions may be enlarged in the drawings. Although the figures show layers and regions with clean lines and boundaries, some or all of these lines and/or boundaries may be idealized. In reality, the boundaries and/or lines may be unobservable, blended, and/or irregular.

DETAILED DESCRIPTION

“Including” and “comprising” (and all forms and tenses thereof) are used herein to be open ended terms. Thus, whenever a claim employs any form of “include” or “comprise” (e.g., comprises, includes, comprising, including, having, etc.) as a preamble or within a claim recitation of any kind, it is to be understood that additional elements, terms, etc., may be present without falling outside the scope of the corresponding claim or recitation. As used herein, when the phrase “at least” is used as the transition term in, for example, a preamble of a claim, it is open-ended in the same manner as the term “comprising” and “including” are open ended. The term “and/or” when used, for example, in a form such as A, B, and/or C refers to any combination or subset of A, B, C such as (1) A alone, (2) B alone, (3) C alone, (4) A with B, (5) A with C, (6) B with C, or (7) A with B and with C. As used herein in the context of describing structures, components, items, objects and/or things, the phrase “at least one of A and B” is intended to refer to implementations including any of (1) at least one A, (2) at least one B, or (3) at least one A and at least one B. Similarly, as used herein in the context of describing structures, components, items, objects and/or things, the phrase “at least one of A or B” is intended to refer to implementations including any of (1) at least one A, (2) at least one B, or (3) at least one A and at least one B. As used herein in the context of describing the performance or execution of processes, instructions, actions, activities and/or steps, the phrase “at least one of A and B” is intended to refer to implementations including any of (1) at least one A, (2) at least one B, or (3) at least one A and at least one B. Similarly, as used herein in the context of describing the performance or execution of processes, instructions, actions, activities and/or steps, the phrase “at least one of A or B” is intended to refer to implementations including any of (1) at least one A, (2) at least one B, or (3) at least one A and at least one B.

As used herein, unless otherwise stated, the term “above” describes the relationship of two parts relative to Earth. A first part is above a second part, if the second part has at least one part between Earth and the first part. Likewise, as used herein, a first part is “below” a second part when the first part is closer to the Earth than the second part. As noted above, a first part can be above or below a second part with one or more of: other parts therebetween, without other parts therebetween, with the first and second parts touching, or without the first and second parts being in direct contact with one another.

As used in this patent, stating that any part (e.g., a layer, film, area, region, or plate) is in any way on (e.g., positioned on, located on, disposed on, or formed on, etc.) another part, indicates that the referenced part is either in contact with the other part, or that the referenced part is above the other part with one or more intermediate part(s) located therebetween.

As used herein, connection references (e.g., attached, coupled, connected, and joined) may include intermediate members between the elements referenced by the connection reference and/or relative movement between those elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and/or in fixed relation to each other. As used herein, stating that any part is in “contact” with another part is defined to mean that there is no intermediate part between the two parts.

Unless specifically stated otherwise, descriptors such as “first,” “second,” “third,” etc., are used herein without imputing or otherwise indicating any meaning of priority, physical order, arrangement in a list, and/or ordering in any way, but are merely used as labels and/or arbitrary names to distinguish elements for ease of understanding the disclosed examples. In some examples, the descriptor “first” may be used to refer to an element in the detailed description, while the same element may be referred to in a claim with a different descriptor such as “second” or “third.” In such instances, it should be understood that such descriptors are used merely for identifying those elements distinctly that might, for example, otherwise share a same name.

The terms “forward” and “aft” refer to relative positions within a gas turbine engine, pump, or vehicle, and refer to the normal operational attitude of the gas turbine engine, pump, or vehicle. For example, with regard to a gas turbine engine, forward refers to a position closer to an engine inlet and aft refers to a position closer to an engine nozzle or exhaust. Further, with regard to a pump, forward refers to a position closer to a pump inlet and aft refers to a position closer to an end of the pump opposite the inlet.

The terms “upstream” and “downstream” refer to the relative direction with respect to a flow in a pathway. For example, with respect to a fluid flow, “upstream” refers to the direction from which the fluid flows, and “downstream” refers to the direction to which the fluid flows.

As used herein, “radially” is used to express a point or points along a radial vector originating at a central axis of a rotating body and pointing perpendicularly outward from the central axis. In some examples, two gears are said to be radially connected or coupled, meaning that the two gears are in physical contact with each other at point(s) along the circumferential outer edge surface of the gears via interlocking gear teeth. In some examples, two pulleys are said to be radially connected or coupled, meaning that the two pulleys are in physical contact with a drive belt at point(s) along the circumferential outer edge surface of the pulleys.

As used herein, the phrase “in communication,” including variations thereof, encompasses direct communication and/or indirect communication through one or more intermediary components, and does not require direct physical (e.g., wired) communication and/or constant communication, but rather additionally includes selective communication at periodic intervals, scheduled intervals, aperiodic intervals, and/or one-time events.

As used herein, “processor circuitry” is defined to include (i) one or more special purpose electrical circuits structured to perform specific operation(s) and including one or more semiconductor-based logic devices (e.g., electrical hardware implemented by one or more transistors), and/or (ii) one or more general purpose semiconductor-based electrical circuits programmable with instructions to perform specific operations and including one or more semiconductor-based logic devices (e.g., electrical hardware implemented by one or more transistors). Examples of processor circuitry include programmable microprocessors, Field Programmable Gate Arrays (FPGAs) that may instantiate instructions, Central Processor Units (CPUs), Graphics Processor Units (GPUs), Digital Signal Processors (DSPs), XPUs, or microcontrollers and integrated circuits such as Application Specific Integrated Circuits (ASICs). For example, an XPU may be implemented by a heterogeneous computing system including multiple types of processor circuitry (e.g., one or more FPGAs, one or more CPUs, one or more GPUs, one or more DSPs, etc., and/or a combination thereof) and application programming interface(s) (API(s)) that may assign computing task(s) to whichever one(s) of the multiple types of processor circuitry is/are best suited to execute the computing task(s).

Centrifugal fluid pumps move fluid through systems by converting rotational kinetic energy of an impeller to hydrodynamic energy of a flowing fluid. In other words, the angular velocity of the impeller is directly proportional to the flow rate of the flowing fluid exiting the pump. Typically, the impeller provides a change in rotational kinetic energy from an electric motor applying mechanical work to an impeller shaft coupled to the impeller and to the rotor of the electric motor. The rotor provides a change in mechanical work over a period of time (e.g., mechanical power) from a stator in the electric motor applying electromagnetic forces to the rotor in the form of torque. If the motor supplies a constant amount of electrical energy to the stator, then the rotor supplies a constant amount of mechanical energy to the impeller. In this case, the mechanical power supplied to the pump by the electric motor is equal to the quotient of the rotational kinetic energy and the amount of time the power is being supplied. In rotational systems, such as a centrifugal fluid pump, the mechanical power of the impeller is equal to the product of the torque and the angular velocity. When the rotor of the electric motor and the impeller shaft of the centrifugal fluid pump are coupled axially (e.g., by a magnetic coupling), then the torque and angular velocity of the rotor transfer to the impeller, via the coupled shafts, and have the same values.

In some examples of fluid pump systems, a motor shaft (e.g., a rotor) can be coupled to an impeller shaft via a magnetic coupling. Magnetic couplings transfer torque between two shafts without physical contact between the shafts. In some examples, the magnetic coupling can be in the form of an inner hub fastened to a first shaft (e.g., an impeller shaft) and an outer hub fastened to a second shaft (e.g., a rotor shaft). In the example outer hub, there are a series of magnets (e.g., bar magnets) positioned to surround the example inner hub with each magnet having an opposite charge of the preceding magnet in the series. In the inner hub, a similar series of magnets are positioned around an axis of rotation of the first shaft Because magnets of opposite charges are attracted to each other via magnetic fields, when the outer hub is positioned around the inner hub, a rotation of the outer hub causes the inner hub to rotate at the same rate. In other words, the example inner hub and the example outer hub are rotatably interlocked. This type of magnetic coupling can be referred to as a co-axial magnetic coupling. Because there is no physical contact between the inner hub and outer hub of the co-axial magnetic coupling, a containment barrier can be fastened to the housing surrounding the inner hub such that no fluid can pass from the inner hub side to the outer hub side.

Problems exist in such fluid pump systems where the presence of an electric motor increases the weight of the pump system, and the separation of the magnetic coupling and a clutch mechanism introduce more components that are prone to failure. Introducing more components that could fail and increasing a weight of the pump system increases testing required of the pump system to ensure that various standards are met and weight requirements are met (so that the aircraft or any other system utilizing a pump system operate properly).

Certain examples provide an integrated magnetic coupler and clutch design that reduces components and eliminates a need for a separate electric motor to drive the fluid pump system. As discussed further below, certain examples provide a fluid pump system that integrates a magnetic coupler and a clutch where the fluid pump system can be driven by the main engine shaft of the aircraft. Alternatively, the magnetic coupler and clutch disclosed below can be used in other applications using clutches such as automobile transmissions, pump systems, etc.

FIG.1is a side view of an example aircraft10. As shown, the aircraft10includes a fuselage12and a pair of wings14(one is shown) extending outward from the fuselage12. In the illustrated example ofFIG.1, a gas turbine engine100is supported on each wing14to propel the aircraft through the air during flight. Additionally, as shown, the aircraft10includes a vertical stabilizer16and a pair of horizontal stabilizers18(one is shown). However, in alternative examples, the aircraft10may be configured differently, such as with a different number and/or type of engines.

Furthermore, the aircraft10may include a thermal management system200for transferring heat between fluids supporting the operation of the aircraft10. More specifically, the aircraft10may include one or more accessory systems configured to support the operation of the aircraft10. For example, such accessory systems include a lubrication system that lubricates components of the engines100, a cooling system that provides cooling air to components of the engines100, an environmental control system that provides cooled air to the cabin of the aircraft10, and/or the like. In such examples, the thermal management system200is configured to transfer heat to and/or from one or more fluids supporting the operation of the aircraft10(e.g., the oil of the lubrication system, the air of the cooling system and/or the environmental control system, and/or the like) from and/or to one or more other fluids supporting the operation of the aircraft10(e.g., the fuel supplied to the engines100). However, in alternative examples, the thermal management system200may be configured to transfer heat between other fluids supporting the operation of the aircraft10.

In addition to the thermal management system200, the aircraft10is subjected to various forces during operation which include aerodynamic forces (e.g., lift, thrust, drag, gravity), vibration forces, shear forces, etc. As such, components within the aircraft10(e.g., such as the example thermal management system200, the engine100, etc.) need to withstand such forces without failure to ensure the aircraft10functions properly. Failure to the thermal management system200due to excessive forces can lead to failure of the engine100or failure to other systems on the aircraft10. In some examples, the thermal management system200can prevent failures by proactively shutting down or disengaging components.

The configuration of the aircraft10described above and shown inFIG.1is provided only to place the present subject matter in an example field of use. Thus, the present subject matter may be readily adaptable to any manner of aircraft, any other suitable heat transfer application (e.g., other similar pump environment), and/or any other suitable low torque transmission application.

FIG.2is a schematic cross-sectional view of an example gas turbine engine100. In the illustrated example, the engine100is configured as a high-bypass turbofan engine. However, in alternative examples, the engine100may be configured as a propfan engine, a turbojet engine, a turboprop engine, a turboshaft gas turbine engine, or any other suitable type of gas turbine engine.

In general, the engine100extends along an axial centerline102and includes a fan104, a low-pressure (LP) spool106, and a high pressure (HP) spool108at least partially encased by an annular nacelle110. More specifically, the fan104may include a fan rotor112and a plurality of fan blades114(one is shown) coupled to the fan rotor112. In this respect, the fan blades114are circumferentially spaced apart and extend radially outward from the fan rotor112. Moreover, the LP and HP spools106,108are positioned downstream from the fan104along the axial centerline102. As shown, the LP spool106is rotatably coupled to the fan rotor112, thereby permitting the LP spool106to rotate the fan blades114. Additionally, a plurality of outlet guide vanes or struts116circumferentially spaced apart from each other and extend radially between an outer casing118surrounding the LP and HP spools106,108and the nacelle110. As such, the struts116support the nacelle110relative to the outer casing118such that the outer casing118and the nacelle110define a bypass airflow passage120positioned therebetween.

The outer casing118generally surrounds or encases, in serial flow order, a compressor section122, a combustion section124, a turbine section126, and an exhaust section128. In some examples, the thermal management system200disclosed above is encased in the outer casing118. Encasing the thermal management system200in the outer casing118can allow the thermal management system200to be powered by the engine100. In some examples, the compressor section122may include a low-pressure (LP) compressor130of the LP spool106and a high-pressure (HP) compressor132of the HP spool108positioned downstream from the LP compressor130along the axial centerline102. Each compressor130,132may, in turn, include one or more rows of stator vanes134interdigitated with one or more rows of compressor rotor blades136. As such, the compressors130,132define a compressed air flow path133extending therethrough. Moreover, in some examples, the turbine section126includes a high-pressure (HP) turbine138of the HP spool108and a low-pressure (LP) turbine140of the LP spool106positioned downstream from the HP turbine138along the axial centerline102. Each turbine138,140may, in turn, include one or more rows of stator vanes142interdigitated with one or more rows of turbine rotor blades144.

Additionally, the LP spool106includes the low-pressure (LP) shaft146and the HP spool108includes a high pressure (HP) shaft148positioned concentrically around the LP shaft146. In such examples, the HP shaft148rotatably couples the turbine rotor blades144of the HP turbine138and the compressor rotor blades136of the HP compressor132such that rotation of the turbine rotor blades144of the HP turbine138rotatably drives the compressor rotor blades136of the HP compressor132. As shown, the LP shaft146is directly coupled to the turbine rotor blades144of the LP turbine140and the compressor rotor blades136of the LP compressor130. Furthermore, the LP shaft146is coupled to the fan104via a gearbox150. In this respect, the rotation of the turbine rotor blades144of the LP turbine140rotatably drives the compressor rotor blades136of the LP compressor130and the fan blades114.

In some examples, the engine100may generate thrust to propel an aircraft. More specifically, during operation, air (indicated by arrow152) enters an inlet portion154of the engine100. The fan104supplies a first portion (indicated by arrow156) of the air152to the bypass airflow passage120and a second portion (indicated by arrow158) of the air152to the compressor section122. The second portion158of the air152first flows through the LP compressor130in which the compressor rotor blades136therein progressively compress the second portion158of the air152. Next, the second portion158of the air152flows through the HP compressor132in which the compressor rotor blades136therein continue to progressively compress the second portion158of the air152. The compressed second portion158of the air152is subsequently delivered to the combustion section124. In the combustion section124, the second portion158of the air152mixes with fuel and burns to generate high-temperature and high-pressure combustion gases160. Thereafter, the combustion gases160flow through the HP turbine138which the turbine rotor blades144of the HP turbine138extract a first portion of kinetic and/or thermal energy therefrom. This energy extraction rotates the HP shaft148, thereby driving the HP compressor132. The combustion gases160then flow through the LP turbine140in which the turbine rotor blades144of the LP turbine140extract a second portion of kinetic and/or thermal energy therefrom. This energy extraction rotates the LP shaft146, thereby driving the LP compressor130and the fan104via the gearbox150. The combustion gases160then exit the engine100through the exhaust section128.

As mentioned above, the aircraft10may include a thermal management system200for transferring heat between fluids supporting the operation of the aircraft10. In this respect, the thermal management system200may be positioned within the engine100. For example, as shown inFIG.2, the thermal management system200is positioned within the outer casing118of the engine100. However, in alternative examples, the thermal management system200may be positioned at any other suitable location within the engine100.

Furthermore, in some examples, the engine100defines a third-stream flow path170. In general, the third-stream flow path170extends from the compressed air flow path133defined by the compressor section122to the bypass airflow passage120. In this respect, the third-stream flow path170allows a portion of the compressed air158from the compressor section122to bypass the combustion section124. More specifically, in some examples, the third-stream flow path170may define a concentric or non-concentric passage relative to the compressed air flow path158downstream of one or more of the compressors130,132or the fan104. The third-stream flow path170may be configured to selectively remove a portion of compressed air158from the compressed air flow path158via one or more variable guide vanes, nozzles, or other actuatable flow control structures. In addition, as will be described below, in some examples, the thermal management system200may transfer heat to the air flowing through the third-stream flow path170. However, a pressure and/or a flow rate of a fluid (e.g., a heat exchange fluid such as a supercritical fluid (e.g., supercritical carbon dioxide (sCO2), etc.)) within the thermal management system200limits a rate at which thermal energy is transferred between the air and the heat exchange fluid. Additionally, it is advantageous for the thermal management system200to produce the pressure and/or the flow rate with components (e.g., pump systems) that minimize and/or otherwise reduce a physical size of the thermal management system200and/or the components (e.g., pump systems) included therein. Moreover, the thermal management system200may help ensure that the heat exchange fluid is free of contaminants when thermal energy is to be transferred.

The example thermal management system200, as described above, helps ensure proper operation of the aircraft10. As such, the thermal management system200is operational to support the operation of the aircraft10. The thermal management system200can include a pump system to move fluid throughout the thermal management system200to support heat transfer functionality. Pump systems can include clutch engagement and disengagement mechanisms to help ensure the pump system is operating appropriately. As disclosed above, pump systems can include proactive measures to help reduce or prevent component failure (e.g., proactive disengagement of a clutching mechanism, reducing moving components within the pump system, etc.). As disclosed herein, pump systems can include integrated magnetic coupling and clutching mechanisms for engaging/disengaging shafts providing a torque output and reducing components/weight in the pump system.

The configuration of the gas turbine engine100described above and shown inFIG.2is provided only to place the present subject matter in an example field of use. Thus, the present subject matter may be readily adaptable to any manner of gas turbine engine configuration, including other types of aviation-based gas turbine engines, marine-based gas turbine engines, and/or land-based/industrial gas turbine engines. Additionally, the present subject matter may be readily adaptable to other kinds of low torque transmission applications.

FIG.3is a schematic view of an example implementation of the thermal management system200for transferring heat between fluids. In general, the thermal management system200will be discussed in the context of the aircraft10and the gas turbine engine100described above and shown inFIGS.1and2. However, the disclosed thermal management system200may be implemented within other aircraft and/or any gas turbine engine configuration and/or any alternative configuration using a thermal management system, a pump system, or a clutch in general such as an automobile transmission.

As shown, the thermal management system200includes a thermal transfer bus202. Specifically, in several examples, the thermal transfer bus202is configured as one or more fluid conduits through which a fluid (e.g., a heat exchange fluid) flows. As will be described below, the heat exchange fluid flows through various heat exchangers such that heat is added to and/or removed from the heat exchange fluid. In this respect, the heat exchange fluid may be any suitable fluid, such as supercritical carbon dioxide. Moreover, in such examples, the thermal management system200includes a pump204configured to pump the heat exchange fluid through the thermal transfer bus202.

Additionally, the thermal management system200includes one or more heat source heat exchangers206arranged along the thermal transfer bus202. More specifically, the heat source heat exchanger(s)206is fluidly coupled to the thermal transfer bus202such that the heat exchange fluid flows through the heat source heat exchanger(s)206. In this respect, the heat source heat exchanger(s)206is configured to transfer heat from fluids supporting the operation of the aircraft10to the heat exchange fluid, thereby cooling the fluids supporting the operation of the aircraft10. Thus, the heat source heat exchanger(s)206adds heat to the heat exchange fluid. AlthoughFIG.3illustrates two heat source heat exchangers206, the thermal management system200may include a single heat source heat exchanger206or three or more heat source heat exchangers206.

The heat source heat exchanger(s)206may correspond to any suitable heat exchanger(s) that cool a fluid supporting the operation of the aircraft10. In one example, at least one of the heat source heat exchangers206is a heat exchanger(s) of the lubrication system(s) of the engine(s)100. In such an example, this heat exchanger(s)206transfers heat from the oil lubricating the engine(s)100to the heat transfer fluid. In another example, at least one of the heat source heat exchangers206is a heat exchanger(s) of the cooling system of the engine(s)100. In such an example, this heat exchanger(s)206transfers heat from the cooling air bled from the compressor section(s)122(or a compressor discharge plenum) of the engine(s)100to the heat transfer fluid. However, in alternative examples, the heat source heat exchanger(s)206may correspond to any other suitable heat exchangers that cool a fluid supporting the operation of the aircraft10.

Furthermore, the thermal management system200includes a plurality of heat sink heat exchangers208arranged along the thermal transfer bus202. More specifically, the heat sink heat exchangers208are fluidly coupled to the thermal transfer bus202such that the heat exchange fluid flows through the heat sink heat exchangers208. In this respect, the heat sink heat exchangers208are configured to transfer heat from the heat exchange fluid to other fluids supporting the operation of the aircraft10, thereby heating the other fluids supporting the operation of the aircraft10. Thus, the heat sink heat exchangers208remove heat from the heat exchange fluid. AlthoughFIG.3illustrates two heat sink heat exchangers208, the thermal management system200may include three or more heat sink heat exchangers208.

The heat sink heat exchangers208may correspond to any suitable heat exchangers that heat a fluid supporting the operation of the aircraft10. For example, at least one of the heat sink heat exchangers208is a heat exchanger(s) of the fuel system(s) of the engine(s)100. In such an example, the fuel system heat exchanger(s)208transfers heat from the heat transfer fluid to the fuel supplied to the engine(s)100. In another embodiment, at least one of the heat sink heat exchangers208is a heat exchanger(s) in contact with the air156flowing through the bypass airflow passage(s)120of the engine(s)100. In such an example, this heat exchanger(s)208transfers heat from the heat exchange fluid to the air156flowing through the bypass airflow passage(s)120.

In several examples, one or more of the heat sink heat exchangers208are configured to transfer heat to the air flowing through the third-stream flow path170. In such examples, the heat exchanger(s)208is in contact with the air flow through the third-stream flow path170. Thus, heat from the heat exchange fluid flowing through the thermal transfer bus202may be transferred to the air flow through the third-stream flow path170. The use of the third-stream flow path170as a heat sink for the thermal management system200provides one or more technical advantages. For example, the third-stream flow path170provides greater cooling than other sources of bleed air because a larger volume of air flows through the third-stream flow path170than other bleed air flow paths. Moreover, the air flowing through third-stream flow path170is cooler than the air flowing through other bleed air flow paths and the compressor bleed air. Additionally, the air in the third-stream flow path170is pressurized, thereby allowing the heat exchanger(s)208to be smaller than heat exchangers relying on other heat sinks within the engine. Furthermore, in examples in which the engine100is unducted, using the third-stream flow path170as a heat sink does not increase drag on the engine100unlike the use of ambient air (e.g., a heat exchanger in contact with air flowing around the engine100). However, in alternative examples, the heat sink heat exchangers208may correspond to any other suitable heat exchangers that heats a fluid supporting the operation of the aircraft10.

Moreover, in several examples, the thermal management system200includes one or more bypass conduits210. Specifically, as shown in the example ofFIG.3, each bypass conduit210is fluidly coupled to the thermal transfer bus202such that the bypass conduit210allows at least a portion of the heat exchange fluid to bypass one of the heat exchangers206,208. In some examples, the heat exchange fluid bypasses one or more of the heat exchangers206,208to adjust the temperature of the heat exchange fluid within the thermal transfer bus202. The flow of example heat exchange fluid through the bypass conduit(s)210is controlled to regulate the pressure of the heat exchange fluid within the thermal transfer bus202. In the illustrated example ofFIG.3, each heat exchanger206,208has a corresponding bypass conduit210. However, in alternative examples, any number of heat exchangers206,208may have a corresponding bypass conduit210so long as there is at least one bypass conduit210.

Additionally, in several examples, the thermal management system200includes one or more heat source valves212and one or more heat sink valves214. In general, each heat source valve212is configured to control the flow of the heat exchange fluid through a bypass conduit210that bypasses a heat source heat exchanger206. Similarly, each heat sink valve214is configured to control the flow of the heat exchange fluid through a bypass conduit210that bypasses a heat sink heat exchanger208. In this respect, each valve212,214is fluidly coupled to the thermal transfer bus202and a corresponding bypass conduit210. As such, each valve212,214may be moved between fully and/or partially opened and/or closed positions to selectively occlude the flow of heat exchange through its corresponding bypass conduit210.

The valves212,214are controlled based on the pressure of the heat exchange fluid within the thermal transfer bus202. More specifically, as indicated above, in certain instances, the pressure of the heat exchange fluid flowing through the thermal transfer bus202may fall outside of a desired pressure range. When the pressure of the heat exchange fluid is too high, the thermal management system200may incur accelerated wear. In this respect, when the pressure of the heat exchange fluid within the thermal transfer bus202exceeds a maximum or otherwise increased pressure value, one or more heat source valves212open. In such instances, at least a portion of the heat exchange fluid flows through the bypass conduits210instead of the heat source heat exchanger(s)206. Thus, less heat is added to the heat exchange fluid by the heat source heat exchanger(s)206, thereby reducing the temperature and, thus, the pressure of the fluid. In several embodiments, the maximum pressure value is between 3800 and 4000 pounds per square inch or less. In some embodiments, the maximum pressure value is between 2700 and 2900 pounds per square inch, such as 2800 pounds per square inch. In other embodiments, the maximum pressure value is between 1300 and 1500 pounds per square inch, such as 1400 pounds per square inch. Such maximum pressure values generally prevent the thermal management system200from incurring accelerated wear.

In some examples, the maximum pressure value is set prior to and/or during operation based on parameters (e.g., materials utilized, pump204design, aircraft10design, gas turbine engine100design, heat exchange fluid, etc.) associated with the thermal management system200. The example maximum pressure value can be adjusted relative to the pressure capacities of the thermal transfer bus202, the pump204, the heat exchangers206,208, the bypass conduit(s)210, and/or the valves212,214. Some examples of pump204architecture that influence example maximum pressure capacities are described in greater detail below.

Conversely, when the pressure of the heat exchange fluid is too low, the pump204may experience operability problems and increased wear. As such, when the pressure of the heat exchange fluid within the thermal transfer bus202falls below a minimum or otherwise reduced pressure value, one or more heat sink valves214open. In such instances, at least a portion of the heat exchange fluid flows through the bypass conduits210instead of the heat sink heat exchangers208. Thus, less heat is removed from the heat exchange fluid by the heat sink heat exchangers208, thereby increasing the temperature and, thus, the pressure of the fluid. In several examples, the minimum pressure value is 1070 pounds per square inch or more. In some examples, the minimum pressure value is between 1150 and 1350 pounds per square inch, such as 1250 pounds per square inch. In other examples, the minimum pressure value is between 2400 and 2600 pounds per square inch, such as 2500 pounds per square inch. Such minimum pressure values are generally utilized when the heat exchange fluid is in a supercritical state (e.g., when the heat exchange fluid is carbon dioxide).

As such, the thermal management system200may be configured to operate such that the pressure of the heat transport fluid is maintained with a range extending between the minimum and maximum pressure values. In some examples, the range extends from 1070 to 4000 pounds per square inch. Specifically, in one example, the range extends from 1250 to 1400 pounds per square inch. In another example, range extends from 2500 to 2800 pounds per square inch.

Accordingly, the operation of the pump204and the valves212,214allows the disclosed thermal management system200to maintain the pressure of the heat exchange fluid within the thermal transfer bus202within a specified range of values as the thermal load placed on the thermal management system200varies.

Furthermore, the example pump204drives the flow of the heat exchange fluid through the thermal management system200. In some examples, the thermal management system200includes one pump204or a plurality of pumps204depending on the desired flow rate, delta pressure across the pump204, and/or the kinetic energy loss of the heat exchange fluid in the thermal transfer bus202. For example, the pump204may increase the output pressure head to accelerate the flow of the heat exchange fluid to a first flowrate. As the heat exchange fluid passes through the thermal transfer bus202, the example kinetic energy of the heat exchange fluid dissipates due to friction, temperature variations, etc. Due to the kinetic energy losses, the heat exchange fluid decelerates to a second flow rate at some point upstream of the pump204. If the example second flow rate is below a desired operating flow rate of the heat exchange fluid, then the pump204can either be of a different architecture that outputs a higher first flow rate, or one or more additional pumps204can be included in the thermal management system200.

As disclosed above, the example pump204is important for proper functionality of the engine100and subsequently the aircraft10. Failure to the pump204can result in increases in temperature of the fluid, insufficient pressure of the fluid, and/or insufficient fluid flow rate of the fluid moving throughout the thermal management system200. Such failures can occur due to excessive forces within the pump204, failure of components within the pump204, insufficient reaction time to detect failures, etc. As discussed further below, examples disclosed herein provide an improved magnetic clutch and coupling mechanism for reducing moving parts, weight, and complexity within the pump204.

FIG.4illustrates an example thermal transport bus pump400(e.g., a magnetically driven pump, a canned motor pump, a fluid pump, a sCO2 pump, the pump204ofFIG.3, etc.). In the illustrated example ofFIG.4, the thermal transport bus pump400drives a fluid (e.g., heat exchange fluid such as sCO2, etc.) through one or more fluid conduits402connected to a flowline (e.g., the thermal transfer bus202ofFIG.3). Specifically, the fluid flows through an inlet pipe404and encounters an impeller406(e.g., a compressor wheel) that rotates to drive the fluid through a compressor collector408(e.g., a volute housing) fluidly coupled to the fluid conduit(s)402. In turn, the fluid conduit(s)402can feed the fluid to one or more heat exchangers (e.g., the heat source heat exchanger206and/or the heat sink heat exchanger208ofFIG.3). Accordingly, the thermal transport bus pump400can pump the fluid to manage a thermal energy of working fluids associated with the aircraft10ofFIG.1, the gas turbine engine100ofFIG.2, and/or any other suitable system.

In some examples, a rotor shaft438(e.g., an input shaft) is coupled to the gearbox150(shown inFIG.2, not shown inFIG.4) and is driven by the rotation of the fan blades114of the engine100. The impeller406is indirectly driven by the gearbox150through the rotor shaft438. In other examples, the rotor shaft438can be coupled to a motor (not shown in this view) driving the rotation of the rotor shaft438. The integration of the flux-modulated permanent magnet clutch in the example ofFIG.4disclosed herein eliminates the need for a motor to drive the rotor shaft438. As such, and disclosed further herein, the thermal transport bus pump400can operate via the main gearbox (e.g., the gearbox150) within the engine100.

As illustrated inFIG.4, a flux-modulated permanent magnet clutch440(also referred to as a magnetic clutch) includes an outer ring of permanent magnets450, a barrier can452, a flux modulator ring455, and an inner ring of permanent magnets460. The flux modulator ring455is coupled to the rotor shaft438and the inner ring of permanent magnets460is coupled to an output shaft (e.g., an impeller shaft466).

In the illustrated example ofFIG.4, an aft end of the outer ring of permanent magnets450(e.g., a female magnetic coupling) is positioned around a forward end of the rotor shaft438. The flux modulator ring455is coupled to the rotor shaft438and rotates with the rotor shaft438. As a result, the rotor shaft438drives a rotation of the flux modulator ring455.

In the illustrated example ofFIG.4, the outer ring of permanent magnets450and the flux modulator ring455are positioned around the barrier can452(e.g., a shroud, hermetic boundary, etc.). To couple the barrier can452to a forward bearing housing428, a barrier can retainer454(e.g., a retainer ring) is positioned around a flange456of the barrier can452and coupled to an aft end of the forward bearing housing428via bolts458. Further, an O-ring459is positioned between the flange456of the barrier can452and the barrier can retainer454. The barrier can452hermetically seals the aft end of the forward bearing housing428and, in turn, prevents the fluid from escaping. In some examples, the outer ring of permanent magnets450is coupled to the barrier can452and thus does not rotate with the rotation of the rotor shaft438. In other examples, the outer ring of permanent magnets450is coupled to the forward bearing housing428or another component inside the thermal transport bus pump400that does not rotate. In some examples, the barrier can452is made of a non-magnetic material such as plastic.

In the illustrated example ofFIG.4, the barrier can452is positioned around the inner ring of permanent magnets460(e.g., a male magnetic coupling), which is magnetically couplable to the outer ring of permanent magnets450. Specifically, opposite magnetic poles of the outer ring of permanent magnets450and the inner ring of permanent magnets460are aligned on opposite sides of the barrier can452and the flux modulator ring455are used to magnetically couple the outer ring of permanent magnets450to the inner ring of permanent magnets460. As disclosed in further detail herein, the outer ring of permanent magnets450can move into and out of polar alignment with the inner ring of permanent magnets460(e.g., the magnetic forces of the magnetic poles of the outer ring of permanent magnets450and the inner ring of permanent magnets460are engaged and disengaged with an axial movement of the outer ring of permanent magnets450).

During operation, when the barrier can452is made of a metallic material (e.g., aluminum, steel, etc.), the barrier can452produces thermal energy as a result of encountering the rotating magnetic fields produced by the outer ring of permanent magnets450and the inner ring of permanent magnets460, and the fluid can absorb the heat from the barrier can452through a vent461to prevent the barrier can452from melting. In some examples, a fan drives the fluid circulation through the vent461. In some other examples, the vent461is open to atmospheric air, or another fluid enclosure, which provides the fluid to absorb thermal energy from the barrier can452.

In the illustrated example ofFIG.4, the inner ring of permanent magnets460is coupled to a tie rod462via a top hat464. The tie rod462extends through the forward bearing housing428to couple to the impeller406. Additionally, the inner ring of permanent magnets460is coupled to and/or extends from an impeller shaft466positioned around the tie rod462. Similarly, the impeller shaft466extends through the forward bearing housing428to couple to the impeller406. As a result, the tie rod462and the impeller shaft466cause the impeller406to rotate with the inner ring of permanent magnets460and pump the fluid.

In the illustrated example ofFIG.4, an axial portion468of the impeller shaft466is supported by journal bearing assemblies470. Further, a radial portion472of the impeller shaft466is supported by a thrust bearing assembly474. For example, the journal bearing assemblies470and/or the thrust bearing assembly474can include foil bearings. In some examples, the journal bearing assemblies470and the thrust bearing assembly474are coupled to the forward bearing housing428via bolts. Additionally or alternatively, the thrust bearing assembly474can be coupled to one of the journal bearing assemblies470.

In the illustrated example ofFIG.4, the thermal transport bus pump400includes a secondary flow network having an inlet475in the forward bearing housing428. Specifically, in the secondary flow network, the fluid enters the forward bearing housing428and flows between the radial portion472of the impeller shaft466and the thrust bearing assembly474. Further, in the secondary flow network, a first portion of the fluid flows around the impeller shaft466and into the compressor collector408. A second portion of the fluid in the secondary flow network flows around the impeller shaft466towards the barrier can452. A separation between an aft end of the inner ring of permanent magnets460and the barrier can452enables the fluid to flow past the inner ring of permanent magnets460and back through the impeller shaft466towards the impeller406. Further, the impeller shaft466includes a duct476that guides the fluid flowing therethrough between the backplate432and the impeller406causing the fluid to enter the compressor collector408. Accordingly, as the gearbox150drives the rotation of the rotor shaft438, the impeller406pumps the fluid through the fluid conduit(s)402.

FIG.5is a close-up view of the flux-modulated permanent magnet clutch440ofFIG.4. As illustrated inFIG.5, the outer ring of permanent magnets450and the flux modulator ring455surrounds the barrier can452and the barrier can452surrounds the inner ring of permanent magnets460. As disclosed in connection withFIG.4, the outer ring of permanent magnets450does not rotate with the rotation of the rotor shaft438or the impeller shaft466. In some examples, the outer ring of permanent magnets450is coupled to the barrier can452and axially moves to couple and decouple with the inner ring of permanent magnets460.

The flux modulator ring455is disposed between the outer ring of permanent magnets450and the inner ring of permanent magnets460and modulates a flux between the magnetic poles of the first and inner ring of permanent magnets450,460. In examples disclosed herein, the inclusion of the flux modulator ring455allows the output torque applied to impeller shaft466to be amplified compared to the input torque provided by the rotor shaft438(e.g., a gear ratio of greater than 1 is achieved). In examples disclosed herein, the flux modulator ring455is composed of multiple ferrous metal pieces made from any ferromagnetic material such as alloy steel, cast iron, etc. In examples disclosed herein, the flux modulator ring455implements means for modulating a flux between the outer ring of permanent magnets450and the inner ring of permanent magnets460.

As illustrated inFIG.5, the flux modulator ring455is connected to the rotor shaft438via a flux modulator ring connector510. In some examples, each metal piece of the flux modulator ring455includes a separate connector510. In other examples, each metal piece of the flux modulator ring455is connected together and subsequently connected to the rotor shaft438via a single connector510. As such, any method of connecting the flux modulator ring455to the rotor shaft438can be used herein with the goal of operably rotating the flux modulator ring455with the rotor shaft438.

FIG.6is a schematic of the flux-modulated permanent magnet clutch440. As illustrated inFIG.6, the flux-modulated permanent magnet clutch440includes a clutch610and a coupler620. The clutch610and the coupler620are integrated with the inclusion of the outer ring of permanent magnets450, the flux modulator ring455, and the inner ring of permanent magnets460.

As shown inFIG.6, the rotor shaft438is driven by the gearbox150. In some examples, the engine100includes an accessory gearbox630for driving the rotor shaft438. In such an example, the accessory gearbox630is driven by the gearbox150(e.g., the accessory gearbox630reduces the torque provided by the fan blades114to operate the thermal transport bus pump400).

FIG.7is an axial view of the flux-modulated permanent magnet clutch440ofFIGS.4and/or5. As illustrated inFIG.7, the flux-modulated permanent magnet clutch440includes the outer ring of permanent magnets450(also referred to as an outer ring), the flux modulator ring455(also referred to as an intermediate ring), and the inner ring of permanent magnets460(also referred to as an inner ring). In some examples, the barrier can452is disposed between the flux modulator ring455and the inner ring of permanent magnets460.

As shown inFIG.7, the outer ring of permanent magnets450includes multiple outer magnets710(two magnets of which are referenced inFIG.7with opposite poles). The outer ring of permanent magnets450, as disclosed inFIG.4, does not rotate and can be coupled to the barrier can452. The outer ring of permanent magnets450moves axially to move into and out of polar alignment with the inner ring of permanent magnets460.

The flux modulator ring455includes multiple ferromagnetic metal pieces720(one of which is referenced inFIG.7). The flux modulator ring455, as disclosed in reference toFIG.4, is rotationally coupled to the rotor shaft438.

The inner ring of permanent magnets460includes multiple inner magnets730(two magnets of which are referenced inFIG.7with opposite poles). The inner ring of permanent magnets460, as disclosed in reference toFIG.4, is rotationally coupled to the impeller shaft466.

As shown inFIG.7, the outer ring of permanent magnets450includes twenty-four permanent outer magnets710(e.g., twelve pairs of poles), the flux modulator ring455includes sixteen ferromagnetic metal pieces720, and the inner ring of permanent magnets460includes eight permanent inner magnets730(e.g., four pairs of poles). The output gear ratio can be attained by utilizing Equation 1 below:

GearRatioo⁢u⁢t=Number⁢of⁢ferromagneticpieces⁢in⁢the⁢flux⁢modulator⁢ringNumb⁢e⁢r⁢of⁢pole⁢pairs⁢oninner⁢ring⁢of⁢permanent⁢magnets(Equation⁢1)

As shown in Equation 1, the output gear ratio is the quotient of the number of ferrous metal pieces on the flux modulator ring455and the number of magnetic pole pairs on the inner ring of permanent magnets460. In the example ofFIG.7, the number of ferromagnetic pieces in the flux modulator ring455equals sixteen and the number of pole pairs on the inner ring of permanent magnets460equals four, which equates to a gear ratio of 4:1 (e.g., the output torque of the impeller shaft466is four times higher than the input torque provided by the rotor shaft438). The number of ferromagnetic metal pieces on the flux modulator ring455and pole pairs on the inner ring of permanent magnets460can be interchangeably used herein to achieve a desired gear ratio different than the examples provided herein using the rule set forth in Equation 2:
No.of pole pairs on inner ring+No. of pole pairs on outer ring=Number of ferromagnetic pieces on the flux modulator   (Equation 2)

As shown in Equation 2, the number of ferromagnetic pieces that can be used in the flux modulator ring455to achieve a desired output gear ratio is equal to the number of pole pair on the inner ring of permanent magnets450plus the number of pole pairs on the outer ring of permanent magnets460.

FIG.8is a schematic view of the flux-modulated permanent magnet clutch440in an engaged position. As shown inFIG.8, the flux-modulated permanent magnet clutch440includes a tension spring810for moving the outer ring of permanent magnets450into and out of polar alignment with the inner ring of permanent magnets460. In some examples, each permanent magnet in the outer ring of permanent magnets450includes a tension spring810to move each of the magnets into and out of polar alignment. In other examples, the outer ring of permanent magnets450includes a single tension spring810or a defined number of tension springs810(e.g., one tension spring per pair of poles, etc.) for moving the outer ring of permanent magnets450which moves the outer ring of permanent magnets450into and out of polar alignment with the inner ring of permanent magnets460or the corresponding inner ring of permanent magnets460.

FIGS.9A and9Bare schematic views of the flux-modulated permanent magnet clutch440ofFIGS.4and/or5moving from a disengaged position910into an engaged position920. As shown inFIG.9A, the tension spring810is in a neutral position (e.g., no load applied to the tension spring810). When the tension spring810is in the neutral position, the flux-modulated permanent magnet clutch440is disengaged (e.g., the first permanent magnet450is out of polar alignment with the second permanent magnet460). When the flux-modulated permanent magnet clutch440is disengaged, the rotation of the rotor shaft438does not impart respective torque on the impeller shaft466since the magnetic coupling of the outer ring of permanent magnets450and the inner ring of permanent magnets460has not occurred. In some examples, the first permanent magnet450is coupled to the barrier can452via the tension spring810.

As shown inFIG.9B, a load can be applied to the spring810to move the outer ring of permanent magnets450into polar alignment with the inner ring of permanent magnets460. Such a force can be imparted on the spring810via a clutch switch912(shown inFIGS.9A and9B). The clutch switch912can include any mechanism for imparting a force on a spring810such as using a solenoid switch, a pneumatic/hydraulic switch, etc. When the spring810is loaded, the outer ring of permanent magnets450moves into polar alignment with the inner ring of permanent magnets460and the torque imparted on the rotor shaft438is subsequently driving the impeller shaft466, as disclosed herein. In some examples, the clutch switch912is controlled via a processor executing machine readable instructions to engage or disengage the flux-modulated permanent magnet clutch440. In some examples, the clutch switch912and/or the spring810implement means for coupling the outer ring of permanent magnets450to the inner ring of permanent magnets460.

In some examples, the magnets on the outer ring of permanent magnets450and the inner ring of permanent magnets460have a length of 1.5 inches. In such an example, the outer ring of permanent magnets450is moved 1.5 inches to move into and out of polar alignment with the inner ring of permanent magnets460. More generally, the magnets can be of a length determined by the pump in which the magnets are positioned (e.g., larger pumps may require larger magnets to ensure a secure coupling). The outer ring of permanent magnets450is moved the length of the magnets to engage/disengage the flux-modulated permanent magnet clutch440. The example movement of the magnets to engage/disengage the flux-modulated permanent magnet clutch440should be understood to represent an example engagement and disengagement and can use alternative methods for engaging/disengaging my moving the outer ring of permanent magnets450.

A flowchart representative of example machine readable instructions, which may be executed to configure processor circuitry to control engagement of the example thermal transport bus pump400ofFIG.4, is shown inFIG.10. The machine readable instructions may be one or more executable programs or portion(s) of an executable program for execution by processor circuitry, such as the processor circuitry1112shown in the example processor platform1100discussed below in connection withFIG.11. The program may be embodied in software stored on one or more non-transitory computer readable storage media such as a compact disk (CD), a floppy disk, a hard disk drive (HDD), a solid-state drive (SSD), a digital versatile disk (DVD), a Blu-ray disk, a volatile memory (e.g., Random Access Memory (RAM) of any type, etc.), or a non-volatile memory (e.g., electrically erasable programmable read-only memory (EEPROM), FLASH memory, an HDD, an SSD, etc.) associated with processor circuitry located in one or more hardware devices, but the entire program and/or parts thereof could alternatively be executed by one or more hardware devices other than the processor circuitry and/or embodied in firmware or dedicated hardware. The machine readable instructions may be distributed across multiple hardware devices and/or executed by two or more hardware devices (e.g., a server and a client hardware device). For example, the client hardware device may be implemented by an endpoint client hardware device (e.g., a hardware device associated with a user) or an intermediate client hardware device (e.g., a radio access network (RAN)) gateway that may facilitate communication between a server and an endpoint client hardware device). Similarly, the non-transitory computer readable storage media may include one or more mediums located in one or more hardware devices. Further, although the example program is described with reference to the flowchart illustrated inFIG.10, many other methods of controlling engagement of the example thermal transport bus pump400may alternatively be used. For example, the order of execution of the blocks may be changed, and/or some of the blocks described may be changed, eliminated, or combined. Additionally or alternatively, any or all of the blocks may be implemented by one or more hardware circuits (e.g., processor circuitry, discrete and/or integrated analog and/or digital circuitry, an FPGA, an ASIC, a comparator, an operational-amplifier (op-amp), a logic circuit, etc.) structured to perform the corresponding operation without executing software or firmware. The processor circuitry may be distributed in different network locations and/or local to one or more hardware devices (e.g., a single-core processor (e.g., a single core central processor unit (CPU)), a multi-core processor (e.g., a multi-core CPU, an XPU, etc.) in a single machine, multiple processors distributed across multiple servers of a server rack, multiple processors distributed across one or more server racks, a CPU and/or a FPGA located in the same package (e.g., the same integrated circuit (IC) package or in two or more separate housings, etc.).

The machine readable instructions described herein may be stored in one or more of a compressed format, an encrypted format, a fragmented format, a compiled format, an executable format, a packaged format, etc. Machine readable instructions as described herein may be stored as data or a data structure (e.g., as portions of instructions, code, representations of code, etc.) that may be utilized to create, manufacture, and/or produce machine executable instructions. For example, the machine readable instructions may be fragmented and stored on one or more storage devices and/or computing devices (e.g., servers) located at the same or different locations of a network or collection of networks (e.g., in the cloud, in edge devices, etc.). The machine readable instructions may require one or more of installation, modification, adaptation, updating, combining, supplementing, configuring, decryption, decompression, unpacking, distribution, reassignment, compilation, etc., in order to make them directly readable, interpretable, and/or executable by a computing device and/or other machine. For example, the machine readable instructions may be stored in multiple parts, which are individually compressed, encrypted, and/or stored on separate computing devices, wherein the parts when decrypted, decompressed, and/or combined form a set of machine executable instructions that implement one or more operations that may together form a program such as that described herein.

In another example, the machine readable instructions may be stored in a state in which they may be read by processor circuitry, but require addition of a library (e.g., a dynamic link library (DLL)), a software development kit (SDK), an application programming interface (API), etc., in order to execute the machine readable instructions on a particular computing device or other device. In another example, the machine readable instructions may need to be configured (e.g., settings stored, data input, network addresses recorded, etc.) before the machine readable instructions and/or the corresponding program(s) can be executed in whole or in part. Thus, machine readable media, as used herein, may include machine readable instructions and/or program(s) regardless of the particular format or state of the machine readable instructions and/or program(s) when stored or otherwise at rest or in transit.

The machine readable instructions described herein can be represented by any past, present, or future instruction language, scripting language, programming language, etc. For example, the machine readable instructions may be represented using any of the following languages: C, C++, Java, C#, Perl, Python, JavaScript, HyperText Markup Language (HTML), Structured Query Language (SQL), Swift, etc.

As mentioned above, the example operations ofFIG.10may be implemented using executable instructions (e.g., computer and/or machine readable instructions) stored on one or more non-transitory computer and/or machine readable media such as optical storage devices, magnetic storage devices, an HDD, a flash memory, a read-only memory (ROM), a CD, a DVD, a cache, a RAM of any type, a register, and/or any other storage device or storage disk in which information is stored for any duration (e.g., for extended time periods, permanently, for brief instances, for temporarily buffering, and/or for caching of the information). As used herein, the terms non-transitory computer readable medium, non-transitory computer readable storage medium, non-transitory machine readable medium, and non-transitory machine readable storage medium are expressly defined to include any type of computer readable storage device and/or storage disk and to exclude propagating signals and to exclude transmission media. As used herein, the terms “computer readable storage device” and “machine readable storage device” are defined to include any physical (mechanical and/or electrical) structure to store information, but to exclude propagating signals and to exclude transmission media. Examples of computer readable storage devices and machine readable storage devices include random access memory of any type, read only memory of any type, solid state memory, flash memory, optical discs, magnetic disks, disk drives, and/or redundant array of independent disks (RAID) systems. As used herein, the term “device” refers to physical structure such as mechanical and/or electrical equipment, hardware, and/or circuitry that may or may not be configured by computer readable instructions, machine readable instructions, etc., and/or manufactured to execute computer readable instructions, machine readable instructions, etc.

FIG.10is a flowchart representative of example machine readable instructions and/or example operations1000that may be executed and/or instantiated by processor circuitry to control engagement of the example thermal transport bus pump400. The machine readable instructions and/or the example clutch switch control process1000ofFIG.10begin at block1010, at which a determination is made as to whether the clutch (e.g., the flux-modulated permanent magnet clutch440) is engaged. The example clutch switch control process1000can begin whether the flux-modulated permanent magnet clutch440is engaged or disengaged.

When it is determined that the flux-modulated permanent magnet clutch440is currently engaged (e.g., block1010returns a result of YES), a determination is made as to whether to disengage the flux-modulated permanent magnet clutch440. (Block1020). In some examples, the thermal transport bus pump400ofFIG.4is disengaged due to a lack of sCO2 fluid in the pump, insufficient rotation of the impeller shaft466and/or the rotor shaft438, the engine100is shut down, the sCO2 has not reached the correct phase, and/or any other normal (e.g., non-failure) disengagement of the flux-modulated permanent magnet clutch440.

When it is determined that the flux-modulated permanent magnet clutch440is not currently engaged (e.g., block1010returns a result of NO), a determination is made as to whether the thermal transport bus pump400is ready for engagement of the flux-modulated permanent magnet clutch440. (Block1030). In some examples, the sCO2 within the thermal transport bus pump400needs to be at a certain phase before engagement of the flux-modulated permanent magnet clutch440is allowed. In some such examples, sensors within the thermal transport bus pump400(e.g., temperature sensors, pressure sensors, etc.) ensure that no liquid remains of the sCO2 (e.g., the sCO2 is fully transformed from a liquid phase to a gaseous phase) through monitoring the sensors in the thermal transport bus pump400. In some examples, the engagement of the flux-modulated permanent magnet clutch440is tied to the speed of the fan blades114of the engine100. In such an example, the flux-modulated permanent magnet clutch440might be disengaged until the fan blades114reach a certain speed.

When it is determined that the thermal transport bus pump400is ready for engagement (e.g., block1030returns a result of YES), then the outer ring of permanent magnets450is moved into polar alignment with the inner ring of permanent magnets460to engage the flux-modulated permanent magnet clutch440. (Block1040). In the examples disclosed herein, the engagement of the flux-modulated permanent magnet clutch440is achieved by exerting a load on the tension spring810to move the outer ring of permanent magnets450.

When it is determined that the flux-modulated permanent magnet clutch440is not to be disengaged (e.g., block1020returns a result of NO), when the thermal transport bus pump is not ready for engagement (e.g., block1030returns a result of NO), or when the flux-modulated permanent magnet clutch440is engaged from block1040, a determination is made as to whether a failure of the thermal transport bus pump400has been detected. (Block1050). In some examples, the thermal transport bus pump400includes bearing and other components for proper operation of the thermal transport bus pump400. In some examples, failures or potential failures of those components are detected via sensors distributed throughout the thermal transport bus pump400.

When a failure to the components inside the thermal transport bus pump400has been detected (e.g., block1050returns a result of YES), a second determination is made regarding the current status of the flux-modulated permanent magnet clutch440. (Block1060). In some examples, the status of the engagement or disengagement of the flux-modulated permanent magnet clutch440is a continuous check (e.g., every cycle, every 100 milliseconds, every 1 second, etc.). In other examples, the status of the engagement or disengagement of the flux-modulated permanent magnet clutch440is periodic and is only checked when a status change is desired (e.g., engaged to disengaged, disengaged to engaged, failure detected, etc.).

When it is determined that a failure is present and the flux-modulated permanent magnet clutch440is currently engaged (e.g., block1060returns a result of YES) or when it is determined that the clutch is to be disengaged (e.g., block1020returns a result of YES), the outer ring of permanent magnets450is moved out of polar alignment with the inner ring of permanent magnets460to disengage the flux-modulated permanent magnet clutch440. (Block1070). In the examples disclosed herein, the disengagement of the flux-modulated permanent magnet clutch440is achieved by removing a load on the tension spring810so the tension spring810relaxes to a neutral position.

When it is determined that a failure is present and the flux-modulated permanent magnet clutch440is currently disengaged (e.g., block1060returns a result of NO), the engagement of the flux-modulated permanent magnet clutch440is prohibited. (Block1080). In some examples, the engagement is prohibited by prohibiting the clutch switch912from exerting a force on the spring810to engage the flux-modulated permanent magnet clutch440. In some examples, the prohibition persists until the failure has been resolved (e.g., the component has been replaced, the failure conditions are no longer present, etc.).

When no failure has been detected (e.g., block1050returns a result of NO), when the flux-modulated permanent magnet clutch440is disengaged via block1070, or when the engagement of the flux-modulated permanent magnet clutch440is prohibited via block1080, the example clutch switch control process1000ends. In some examples, the example clutch switch control process1000is executed continuously (e.g., every cycle, every 100 milliseconds, every 1 second, etc.) to check the status of the flux-modulated permanent magnet clutch440.

FIG.11is a block diagram of an example processor platform1100structured to execute and/or instantiate the machine readable instructions and/or the operations ofFIG.10to control engagement of the example thermal transport bus pump400ofFIG.4. The processor platform1100can be, for example, an autopilot system or any other kind of control system, a mobile device, a personal computer, or any other type of computing device.

The processor platform1100of the illustrated example includes processor circuitry1112. The processor circuitry1112of the illustrated example is hardware. For example, the processor circuitry1112can be implemented by one or more integrated circuits, logic circuits, FPGAs, microprocessors, CPUs, GPUs, DSPs, and/or microcontrollers from any desired family or manufacturer. The processor circuitry1112may be implemented by one or more semiconductor based (e.g., silicon based) devices. In this example, the processor circuitry1112implements the example clutch switch control process1000.

The processor circuitry1112of the illustrated example includes a local memory1113(e.g., a cache, registers, etc.). The processor circuitry1112of the illustrated example is in communication with a main memory including a volatile memory1114and a non-volatile memory1116by a bus1118. The volatile memory1114may be implemented by Synchronous Dynamic Random Access Memory (SDRAM), Dynamic Random Access Memory (DRAM), RAMBUS® Dynamic Random Access Memory (RDRAM®), and/or any other type of RAM device. The non-volatile memory1116may be implemented by flash memory and/or any other desired type of memory device. Access to the main memory1114,1116of the illustrated example is controlled by a memory controller1117.

The processor platform1100of the illustrated example also includes interface circuitry1120. The interface circuitry1120may be implemented by hardware in accordance with any type of interface standard, such as an Ethernet interface, a universal serial bus (USB) interface, a Bluetooth® interface, a near field communication (NFC) interface, a Peripheral Component Interconnect (PCI) interface, and/or a Peripheral Component Interconnect Express (PCIe) interface.

In the illustrated example, one or more input devices1122are connected to the interface circuitry1120. The input device(s)1122permit(s) a user to enter data and/or commands into the processor circuitry1112. The input device(s)1122can be implemented by, for example, a sensor, a camera (still or video), a keyboard, a button, and/or any other similar device.

One or more output devices1124are also connected to the interface circuitry1120of the illustrated example. The output device(s)1124can be implemented, for example, by display devices (e.g., a light emitting diode (LED), an organic light emitting diode (OLED), a liquid crystal display (LCD), a cathode ray tube (CRT) display, an in-place switching (IPS) display, a touchscreen, etc.). The interface circuitry1120of the illustrated example, thus, typically includes a graphics driver card, a graphics driver chip, and/or graphics processor circuitry such as a GPU.

The interface circuitry1120of the illustrated example also includes a communication device such as a transmitter, a receiver, a transceiver, a modem, a residential gateway, a wireless access point, and/or a network interface to facilitate exchange of data with external machines (e.g., computing devices of any kind) by a network1126. The communication can be by, for example, an Ethernet connection, a digital subscriber line (DSL) connection, a telephone line connection, a coaxial cable system, a satellite system, a line-of-site wireless system, a cellular telephone system, an optical connection, etc.

The processor platform1100of the illustrated example also includes one or more mass storage devices1128to store software and/or data. Examples of such mass storage devices1128include magnetic storage devices, optical storage devices, floppy disk drives, HDDs, CDs, Blu-ray disk drives, redundant array of independent disks (RAID) systems, solid state storage devices such as flash memory devices and/or SSDs, and DVD drives.

The machine readable instructions1132, which may be implemented by the machine readable instructions ofFIG.10, may be stored in the mass storage device1128, in the volatile memory1114, in the non-volatile memory1116, and/or on a removable non-transitory computer readable storage medium such as a CD or DVD.

In some examples, the processor platform1100implements means for controlling the flux-modulated permanent magnet clutch440by implementing the example clutch switch control process1000ofFIG.10.

From the foregoing, it will be appreciated that example systems, methods, apparatus, and articles of manufacture have been disclosed for a flux-modulated permanent magnet clutch. Examples disclosed herein provide a flux-modulated permanent magnet clutch that eliminates the need for a dedicated motor and a separate clutch mechanism in a thermal transport bus pump for engaging an input shaft with an output shaft. Examples disclosed herein combine a magnetic clutch and a magnetic coupler to reduce moving parts and additional components in a low torque transmission prone to failure.

Example methods, apparatus, systems, and articles of manufacture to a flux-modulated permanent magnet clutch are disclosed herein. Further examples and combinations thereof include the following:

Example 1 includes a magnetic clutch apparatus comprising a tension spring, an outer ring coupled to the tension spring, the outer ring including a first plurality of magnets, an inner ring coupled to an output shaft, the inner ring including a second plurality of magnets, the outer ring to magnetically engage with the inner ring, and an intermediate ring coupled to an input shaft, the intermediate ring disposed between the inner ring and the outer ring, the intermediate ring including a ferrous metal.

Example 2 includes the magnetic clutch apparatus of any preceding clause, further including a hermetic boundary separating the inner ring from the intermediate ring.

Example 3 includes the magnetic clutch apparatus of any preceding clause, wherein the hermetic boundary is made of a non-magnetic material.

Example 4 includes the magnetic clutch apparatus of any preceding clause, wherein the outer ring is coupled to the hermetic boundary via the tension spring.

Example 5 includes the magnetic clutch apparatus of any preceding clause, wherein the intermediate ring includes a plurality of ferrous metal pieces, a number of ferrous metal pieces and a number of magnets on the inner ring based upon a desired gear ratio.

Example 6 includes the magnetic clutch apparatus of any preceding clause, wherein the desired gear ratio is determined by dividing the number of ferrous metal pieces on the intermediate ring by a number of magnetic pole pairs on the inner ring.

Example 7 includes the magnetic clutch apparatus of any preceding clause, wherein the number of ferrous metal pieces on the intermediate ring is equal to a sum of the number of magnetic pole pairs on the inner ring and a number of pole pairs on the outer ring.

Example 8 includes the magnetic clutch apparatus of any preceding clause, further including a clutch switch, the clutch switch to move the outer ring via the tension spring to engage and disengage the magnetic clutch apparatus by moving the inner ring and the outer ring into and out of polar alignment.

Example 9 includes the magnetic clutch apparatus of any preceding clause, wherein the inner ring rotates with the output shaft and the intermediate ring rotates with the input shaft.

Example 10 includes the magnetic clutch apparatus of any preceding clause, wherein the outer ring remains stationary.

Example 11 includes a pump system comprising a rotor shaft coupled to a gearbox, an impeller shaft, the impeller shaft coupled to an impeller, and a magnetic clutch to engage the rotor shaft and the impeller shaft, the magnetic clutch including a tension spring, an outer magnetized ring coupled to the tension spring, the outer magnetized ring including a first plurality of magnets, an inner magnetized ring coupled to the impeller shaft, the inner magnetized ring including a second plurality of magnets, the outer magnetized ring to magnetically engage with the inner magnetized ring, and an intermediate ring coupled to the rotor shaft, the intermediate ring disposed between the inner magnetized ring and the outer magnetized ring, the intermediate ring including a ferrous metal, wherein a first movement of the outer magnetized ring into a polar alignment with the inner magnetized ring engages the magnetic clutch and a second movement of the outer magnetized ring out of polar alignment with the inner magnetized ring disengages the magnetic clutch.

Example 12 includes the pump system of any preceding clause, wherein the magnetic clutch further includes a hermetic boundary separating the inner magnetized ring from the intermediate ring.

Example 13 includes the pump system of any preceding clause, wherein the hermetic boundary is made of a non-magnetic material.

Example 14 includes the pump system of any preceding clause, wherein the outer magnetized ring is coupled to the hermetic boundary via the tension spring.

Example 15 includes the pump system of any preceding clause, further including a clutch switch, the clutch switch to move the outer magnetized ring via the tension spring to engage and disengage the magnetic clutch by moving the inner magnetized ring and outer magnetized ring into and out of polar alignment.

Example 16 includes the pump system of any preceding clause, wherein the inner magnetized ring rotates with the impeller shaft and the intermediate ring rotates with the rotor shaft.

Example 17 includes the pump system of any preceding clause, wherein the outer magnetized remains stationary.

Example 18 includes the pump system of any preceding clause, wherein the intermediate ring includes a plurality of ferrous metal pieces, a number of ferrous metal pieces and a number of magnets on the inner magnetized ring based upon a desired gear ratio.

Example 19 includes the pump system of any preceding clause, wherein the desired gear ratio is determined by dividing the number of ferrous metal pieces on the intermediate ring by a number of magnetic pole pairs on the inner magnetized ring.

Example 20 includes the pump system of any preceding clause, wherein the number of ferrous metal pieces on the intermediate ring is equal to a sum of the number of magnetic pole pairs on the inner ring and a number of pole pairs on the outer ring.

Example 21 includes a method for controlling a magnetic clutch in a pump system, the method comprising determining whether the magnetic clutch is engaged, determining, when the magnetic clutch is not engaged, whether the magnetic clutch is ready for engagement based upon a phase of a fluid, and when the magnetic clutch is ready for engagement, providing a force to a tension spring to move an outer magnetized ring into polar alignment with an inner magnetized ring to engage the magnetic clutch by coupling an input shaft to an output shaft.

Example 22 includes the method of any preceding clause, further including releasing the force from the tension spring to move the outer magnetized ring out of polar alignment with the inner magnetized ring.

Example 23 includes the method of any preceding clause, further including detecting a failure within the pump system and determining an action to take based upon the detection of the failure.

Example 24 includes the method of any preceding clause, further including disengaging the magnetic clutch when a failure has been detected.

Example 25 includes the method of any preceding clause, further including prohibiting the engagement of the magnetic clutch when a failure has been detected.

Example 26 includes an aircraft comprising an engine and a pump system, the pump system comprising a rotor shaft coupled to a gearbox, the gearbox coupled to the engine, an impeller shaft, the impeller shaft coupled to an impeller, and a magnetic clutch to engage the rotor shaft and the impeller shaft, the magnetic clutch including a tension spring, an outer magnetized ring coupled to the tension spring, the outer magnetized ring including a first plurality of magnets, an inner magnetized ring coupled to the impeller shaft, the inner magnetized ring including a second plurality of magnets, the outer magnetized ring to magnetically engage with the inner magnetized ring, and an intermediate ring coupled to the rotor shaft, the intermediate ring disposed between the inner magnetized ring and the outer magnetized ring, the intermediate ring including a ferrous metal, wherein a first movement of the outer magnetized ring into a polar alignment with the inner magnetized ring engages the magnetic clutch and a second movement of the outer magnetized ring out of polar alignment with the inner magnetized ring disengages the magnetic clutch.

Example 27 includes the engine of any preceding clause, wherein the magnetic clutch further includes a hermetic boundary separating the inner magnetized ring from the intermediate ring.

Example 28 includes the engine of any preceding clause, wherein the hermetic boundary is made of a non-magnetic material.

Example 29 includes the engine of any preceding clause, wherein the outer magnetized ring is coupled to the hermetic boundary via the tension spring.

Example 30 includes the engine of any preceding clause, further including a clutch switch, the clutch switch to move the outer magnetized ring via the tension spring to engage and disengage the magnetic clutch by moving the inner magnetized ring and outer magnetized ring into and out of polar alignment.

Example 31 includes the engine of any preceding clause, wherein the inner magnetized ring rotates with the impeller shaft and the intermediate ring rotates with the rotor shaft.

Example 32 includes the engine of any preceding clause, wherein the outer magnetized ring remains stationary.

Example 33 includes the engine of any preceding clause, wherein the intermediate ring includes a plurality of ferrous metal pieces, a number of ferrous metal pieces and a number of magnets on the inner magnetized ring based upon a desired gear ratio.

Example 34 includes the engine of any preceding clause, wherein the desired gear ratio is determined by dividing the number of ferrous metal pieces on the intermediate ring by a number of magnetic pole pairs on the inner magnetized ring.

Example 35 includes the engine of any preceding clause, wherein the number of ferrous metal pieces on the intermediate ring is equal to a sum of the number of magnetic pole pairs on the inner magnetized ring and a number of pole pairs on the outer magnetized ring.

Example 36 includes an apparatus comprising means for modulating a flux between a magnetic outer ring and a magnetic inner ring, means for coupling the magnetic outer ring to the magnetic inner ring, and means for controlling the means for coupling.

The following claims are hereby incorporated into this Detailed Description by this reference. Although certain example systems, methods, apparatus, and articles of manufacture have been disclosed herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all systems, methods, apparatus, and articles of manufacture fairly falling within the scope of the claims of this patent.