BACKGROUND

Field

The present specification generally relates to generator systems and, more specifically, to generator systems and methods for making wet and dry cavity generator systems.

Technical Background

Some current aircraft engines include starter/generator systems that are a motor for starting the aircraft engines and also a generator to provide electrical energy to power systems on the aircraft after starting the aircraft engines. In this regard, the starter/generator systems have a start mode that converts electrical energy into mechanical energy and a generate mode that converts mechanical energy into electrical energy.

Starter/generator systems include a fixed plurality of components and a moving plurality of components that move relative to the fixed plurality of components. The fixed plurality of components include a main stator that includes a housing that provides a cavity therethrough. The moving plurality of components include a main rotor that is located within the cavity that rotates relative to the main stator to induce a voltage within the main stator during the generate mode.

As the main rotor rotates and induces a voltage in the main stator, heat is generated in the cavity. A liquid cooling system may be provided to reduce the heat. The starter/generator systems may be either wet cavity systems or dry cavity systems. In a wet cavity system, the main rotor and main stator are exposed directly to a liquid coolant. In a dry cavity system, the liquid coolant is directed through the cavity within liquid conduits. Both the wet cavity systems and the dry cavity systems have their own advantages and disadvantages.

Conventional methods of forming the starter/generator systems can include any number of manufacturing processes, such as machining, casting etc. For example, oxidized laminations may be stacked to form a core and coils may be formed from insulated wire. Whether the starter/generator systems are either a wet cavity system or a dry cavity system will affect how the starter/generator systems are built. Accordingly, a need exists for other liquid cooling systems and methods of manufacturing the starter/generators with the desired liquid cooling systems, whether wet or dry.

SUMMARY

In one embodiment, a method for manufacturing a main rotor for a generator is provided. The method includes printing at least part of a rotor shaft by a three-dimensional printing process. The step of printing at least part of the rotor shaft includes printing a plurality of closed outlets and a plurality of open outlets. A rotor core is printed by the three-dimensional printing process. The step of printing the rotor core includes printing a plurality of liquid coolant conduits that extend through the rotor core and fluidly connecting the plurality of liquid coolant conduits to the plurality of closed openings.

In another embodiment, a main rotor for a generator system includes a rotor shaft including a plurality of closed outlets printed on an outward-facing circumferential face of the rotor shaft. A plurality of open outlets are printed on the outward-facing circumferential face of the rotor shaft. A rotor core extends about the rotor shaft. The rotor core includes a plurality of liquid coolant conduits printed within the rotor core and fluidly connected with the plurality of closed outlets.

In another embodiment, a generator system includes a main stator and a main rotor located within a cavity of the main stator. The main rotor includes a rotor shaft comprising a plurality of open outlets printed on the outward-facing circumferential face of the rotor shaft. A rotor core extends about the rotor shaft. The rotor core includes a plurality of liquid coolant conduits printed within the rotor core and connected to a closed area of the rotor shaft.

Additional features and advantages of the generator systems described herein, and the components thereof, will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments described herein, including the detailed description which follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein, and together with the description serve to explain the principles and operations of the claimed subject matter.

