Abstract: An air supply controller is configured to supply cooling air to an air cycle machine. The controller includes a chamber having a first inlet configured to receive air from a first source, a second inlet configured to receive air from a second source, and an outlet configured to pass air from first inlet and/or the second inlet to an air cycle machine. A control member is disposed within the chamber and configured to move from a first position to a second position. When the control member is in the first position it obstructs an airflow from the second inlet to the outlet and permits an airflow from the first inlet to the outlet. When the control member is in the second position it obstructs the airflow from the first inlet to the outlet and permits the airflow from the second inlet to the outlet.

Abstract: A turbine housing includes a turbine inlet plenum and a turbine housing body. The turbine housing body includes a turbine outlet mounting face, a seal plate mounting face, and a center bore formed between the turbine outlet mounting face and the seal plate mounting face. A first support is formed about the turbine inlet plenum and in contact with the turbine housing body. A relief pocket is formed in the first support proximate the seal plate mounting face. The relief pocket is formed at a first distance from a turbine housing center axis of the center bore and at a first depth relative to the seal plate mounting face. A ratio of the first distance to the first depth is between 2.66 and 2.90.

Abstract: A motor housing assembly for a cabin air compressor assembly is provided that includes a central body portion, a first end portion, and a second end portion. The central body portion has an internal cavity configured to receive an electric motor. The first end portion includes a first and second motor cooling inlet duct. The second end portion includes a flange configured to couple with an outlet housing of the cabin air compressor assembly. A motor cooling duct centerline is defined between the first and second motor cooling inlet duct and is perpendicular to a central body portion centerline. A first distance is defined between an outer edge of the first and second motor cooling inlet duct. A second distance is defined between an outer face of the flange and an intersection of the centerlines. A ratio of the first distance to the second distance is between 1.29 and 1.3.

Abstract: A recirculation flow collector for a fan includes an arcuate housing; a first face with a first circular opening to receive flow; a second face with a second circular opening to allow flow in a normal fan operating condition; and an outlet in a bottom of the arcuate housing to allow recirculation flow.

Abstract: A seal plate for an air cycle machine includes a substantially disk-shaped body having a first side configured to be coupled to a compressor housing of the air cycle machine and a second side configured to be coupled to a turbine housing of the air cycle machine. The seal plate also includes a timing pin slot configured to align the first side of the seal plate with the compressor housing. The seal plate further includes a plurality of fastener holes distributed radially in an asymmetric pattern. The plurality of fastener holes includes an alignment fastener hole configured to align the second side of the seal plate with the turbine housing. An angular offset between the alignment fastener hole and the timing pin slot is about 38.45 degrees.

Abstract: A disc for a fan rotor (with a pilot to connect to a rotating shaft, a hub and a plurality of blades) includes a flat circular portion connecting to the pilot at an inner edge and to the hub at an outer edge; a plurality of first circular cooling holes of a first diameter located around the inner edge of the disc; and a plurality of second circular cooling holes of a second diameter located around the outer edge of the disc, wherein the second diameter is larger than the first diameter.

Abstract: A journal air bearing is provided. The bearing includes a top foil configured to receive the shaft, an intermediate foil disposed radially outboard the top foil, and a journal sleeve disposed radially outboard the intermediate foil. The intermediate foil defines a plurality of holes configured to act as a vent to communicate fluid to an increased supply area to an air film.

Abstract: An air cycle machine has a housing which holds a compressor section, and a turbine section having an expansion area, and a fan section disposed outside of the housing. A shaft, which attaches to and is coaxial with the compressor section, the turbine section and the fan section, is supported by an air journal bearing and an air thrust bearing. The shaft has a hollow core for porting cooling air from the air journal bearing and the air thrust bearing, and a tube that extends into said expansion area and communicates cooling air from the turbine expansion area to the thrust bearing.

Abstract: A turbine nozzle for an air cycle machine includes a disk having a central axis and a plurality of airfoils extending from a surface of the disk. The plurality of airfoils is arranged radially about the disk section to direct a flow of a fluid passing thereby. A relief cut adjacent the airfoils, wherein the relief cut provides a channel in a least a portion of the surface of the disk.

Abstract: A disc for a fan rotor (with a pilot to connect to a rotating shaft, a hub and a plurality of blades) includes a flat circular portion connecting to the pilot at an inner edge and to the hub at an outer edge; a plurality of first circular cooling holes of a first diameter located around the inner edge of the disc; and a plurality of second circular cooling holes of a second diameter located around the outer edge of the disc, wherein the second diameter is larger than the first diameter.

Abstract: A thrust plate includes an annular-shaped body having a scalloped outer edge that forms a first circumference defined by a first diameter. The thrust plate further includes a plurality of cooling slots formed in a first surface of the body. The cooling slots are formed between each pair of adjacent scallops. A center of each cooling slot extends towards the center of the thrust plate at a common predetermined angle with respect to one another.

Abstract: A motor housing includes a central body having a central cavity region configured to receive an electric motor. Also included is a first end portion having a first inner surface that defines a first internal cavity region configured to receive a first end winding of a stator of the electric motor, wherein the first internal cavity region comprises a first radius defined by a distance from a main axis of the motor housing to the first inner surface. Further included is a second end portion having a second inner surface that defines a second internal cavity region configured to receive a second end winding of the stator, wherein a ratio of the first radius to a first end portion wall thickness ranges from 19.89 to 27.85.

Abstract: A thrust plate includes an annular-shaped body having a scalloped outer edge that forms a first circumference defined by a first diameter. The thrust plate further includes a plurality of cooling slots formed in a first surface of the body. The cooling slots are formed between each pair of adjacent scallops. A center of each cooling slot extends towards the center of the thrust plate at a common predetermined angle with respect to one another.

Abstract: A tie rod for extending between a fan shroud and a shaft cap in a rotative assembly includes a first end with threads; a second end with threads; and an elongated portion between the first end and the second end. The tie rod has diameter to length ratio of about 1 to 40.810 to about 1 to 40.768.

Abstract: A fan housing of a ram air fan assembly is provided including a flange having at least one tab. The at least one tab includes a first portion extending generally perpendicularly from the flange and a second portion extending generally parallel to the flange. A notch is formed by an inclined surface and a curved surface at an intersection between the first portion and the second portion. The second portion is elongated and extends about 0.020 inches beyond a front surface of the first portion.

Abstract: motor housing for a cabin air compressor includes a central body portion having a center wall thickness and an internal cavity that is configured to receive an electric motor, a first end portion having a second internal cavity that is configured to receive a first end winding of the stator, and a second end portion having a third internal cavity configured to receive a second end winding of the stator. A ratio of a wall thickness of either of the first or the second end portions to the motor wall thickness is at least greater than 1.68 to 1.

Abstract: A turbine housing includes a turbine inlet plenum and a turbine housing body. The turbine housing body includes a turbine outlet mounting face, a seal plate mounting face, and a center bore formed between the turbine outlet mounting face and the seal plate mounting face. A first support is formed about the turbine inlet plenum and in contact with the turbine housing body. A relief pocket is formed in the first support proximate the seal plate mounting face. The relief pocket is formed at a first distance from a turbine housing center axis of the center bore and at a first depth relative to the seal plate mounting face. A ratio of the first distance to the first depth is between 2.66 and 2.90.

Abstract: A shaft cap to connect between a shaft and a tie rod on a rotative assembly includes a circular portion with a central opening for connecting to the tie rod; a conical portion extending out from the circular portion at a slope; and a pilot around the outer edge of the conical portion. The pilot includes an outer lip to connect to an end of the shaft, an inner portion to connect to the inner circumference of the shaft and an undercut portion between the outer lip and the inner portion.

Abstract: An air cycle machine has a housing which holds a compressor section, and a turbine section having an expansion area, and a fan section disposed outside of the housing. A shaft, which attaches to and is coaxial with the compressor section, the turbine section and the fan section, is supported by an air journal bearing and an air thrust bearing. The shaft has a hollow core for porting cooling air from the air journal bearing and the air thrust bearing, and a tube that extends into said expansion area and communicates cooling air from the turbine expansion area to the thrust bearing.

Abstract: A fan rotor has a plurality of blades arranged circumferentially about a central axis, wherein the plurality of blades extend between 2.9980 and 3.0020 inches radially from the central axis. The fan rotor has a root portion arranged radially inward from the plurality of blades. The fan rotor also has a web portion that connects the plurality of blades to the root portion, the web portion having a minimum longitudinal thickness between 0.2000 and 0.2100 inches.