High speed magnetic thrust disk

Details High speed magnetic thrust disk High speed magnetic thrust disk

1999-04-28

2001-05-15

Tamai, Karl (Department: 2834)

Electrical generator or motor structure

Dynamoelectric

Rotary

C310S074000, C415S104000, C415S107000

Reexamination Certificate

active

06232688

ABSTRACT:

BACKGROUND OF THE INVENTION
The present invention relates generally to the design and fabrication of a composite structure comprising soft magnetic alloys and high strength fibers. More particularly, the present invention has one form defined by an internally reinforced metal matrix composite thrust disk for use in an electromagnetic thrust bearing. The selectively reinforced regions of the thrust disk contain a high strength iron cobalt metal matrix composite material. Although the present invention was developed for use in gas turbine engines, certain applications may be outside this field.
It is well known that a gas turbine engine integrates a compressor and a turbine having components that rotate at extremely high speeds in a high temperature environment. One component is a rotor disk that carries a plurality of airfoils utilized to influence the gaseous flow within the engine. The rotating components typically cooperate with a rotatable shaft and are supported by radial bearings and a thrust bearing that must withstand significant dynamic and static loads within a hostile environment. During operation of the gas turbine engine, the bearings are subjected to forces including: shock loads, such as from landings; maneuver loads, such as associated with sudden change in direction; and, centrifugal loads attendant with the mass of the rotating components.
The desire to increase efficiency and power output from gas turbine engines has caused many engine designers to consider the application of magnetic bearings for supporting the rotor and rotatable shaft. The integration of magnetic bearings into an engine will enable the rotor and rotatable shaft to be supported by magnetic forces, eliminate frictional forces, eliminate mechanical wear and allow the removal of the lubrication system.
Magnetic thrust bearings include a magnetic flux field and a rotatable thrust disk that is acted upon by the magnetic flux field. The application of magnetic thrust bearings in flight weight gas turbine engines require compactactness of bearing design, which ultimately equates to lighter weight. Prior designers of gas turbine engines have utilized materials for the rotating thrust disk that experience a loss of mechanical properties at elevated temperatures. This loss of mechanical properties limits the maximum rotational speed that the thrust disk can be operated at, thereby effectively limiting the maximum rotational speed of the engine.
Although the prior techniques utilizing magnetic thrust bearings for gas turbine engines are steps in the right direction, the need for additional improvement still remains. The present invention satisfies this need in a novel and unobvious way.
SUMMARY OF THE INVENTION
One aspect of the present invention contemplates a high-speed internally reinforced magnetically responsive thrust member.
In one form of the present invention there is contemplated an apparatus, comprising: a housing; a member rotatable relative to the housing; a magnetically responsive structure coupled to and rotatable with the member, the structure formed of a soft magnetic alloy material with at least a portion of the structure internally reinforced with at least one elongated high strength reinforcing member.
Another form of the present invention contemplates an electromagnetic thrust bearing, comprising: a stator having a stator surface; a rotor having a rotor surface spaced from the stator surface, the rotor having a first internally reinforced portion for inducing a first roll to the rotor to cancel at least a portion of an opposite second roll induced in the rotor by an attractive force between the rotor and the stator.
In yet another form of the present invention there is contemplated an apparatus, comprising: a magnetically responsive member having an iron based soft magnetic alloy portion, the member having a bore formed therein that is internally reinforced with a first high strength magnetic matrix composite zone for controlling bore growth, and wherein the member is internally reinforced with a second high strength magnetic matrix composite zone substantially normal to the first high strength magnetic matrix composite zone, and further wherein the high strength magnetic matrix composite zones include the magnetic alloy and at least one high strength fiber.
One object of the present invention is to provide a unique high speed magnetic thrust disk.
Related objects and advantages of the present invention will be apparent from the following description.


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