Abstract: A compressor rotor compresses air and delivers the compressed air to a downstream inlet and across a turbine rotor. A shaft rotates with the turbine rotor and the compressor rotor. The shaft is hollow with an inner bore and an outer periphery. At least one journal bearing supports a portion of the shaft, and has an inner bore spaced from the outer periphery of the shaft. A cooling air path is provided between the shaft outer periphery and the bearing inner periphery, and along a length of the bearing to at least one connection hole. The connection hole provides cooling air from an outer periphery of the shaft to the inner bore of the shaft. In a separate feature, a shaft for use in an air supply machine includes a hollow interior, with such a connection hole.

Abstract: A ram air fan assembly includes a ram air fan disposed at a fan inlet and a ram air fan motor operably connected to the ram air fan. A blower is operably connected to the ram air fan and is configured to redirect a cooling flow across the ram air fan motor from a substantially axially directed flow to a substantially radially directed flow thereby increasing the cooling flow across the ram air fan motor. A method of cooling a ram air fan assembly includes urging a cooling flow toward the ram air fan motor and is directed across the ram air fan motor thus removing thermal energy from the ram air fan motor. The cooling flow proceeds across a blower operably connected to the ram air fan motor, thus directing the cooling flow substantially radially outwardly toward the fan inlet.

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: 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 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: An exemplary air cycle machine bearing housing includes a housing establishing a bore that receives a bearing. The bearing rotatably supports an air cycle machine shaft. The bore has an axial length and a radial diameter. A ratio of the axial length to the radial diameter is from 0.6989 to 0.7128.

Abstract: An exemplary shaft assembly of an air cycle machine includes a cylindrical body rotatably coupling a compressor rotor, a turbine rotor and a fan rotor. The cylindrical body has an axial length and a diameter. A ratio of the axial length to the diameter is from 34.82 to 35.18.

Abstract: An example fan assembly impeller moves air along a secondary flow path when driven by a motor. The motor also drives a fan rotor to move air along a primary flow path of the fan assembly. Air moving along the primary flow path moves in a first direction. Air moving along the secondary flow path moves in a second direction opposite the first direction. An example fan shroud communicates air used to cool a motor into a primary flow path of a fan assembly. The shroud communicates the air into the primary flow path so that the flow of air is at least partially aligned with air moving through the primary flow path of the fan assembly.

Abstract: A fan shield for an air cycle machine includes a fan shield body in the general shape of a frustum of a cone having curved sides. The curved sides define a radius of curvature and a center point of curvature that corresponds to the radius of curvature. The center point of curvature is an axial distance from a large end of the fan shield body and a radial distance from the central axis such that a ratio of the radial distance to the axial distance is between 1.160 and 1.360. A bearing housing includes a body that defines a cylindrical portion and an annular flange at one end. The annular flange includes a first attachment opening, a second attachment opening and a third attachment opening that are non-uniformly circumferentially spaced around the flange.

Abstract: A fan rotor includes a rotor body that has plurality of fan blades for rotation about a central axis. An annular wall extends radially inward from the rotor body. A hub body extends axially from the annular wall and defines a central hub bore with a hub bore diameter Db. The hub body further defines a first cylindrical hub portion on one axial side of the annular wall and a second cylindrical hub portion on an opposite side of the annular wall. A ratio of the outer diameter of the first cylindrical hub portion to a diameter of the central hub bore is 1.996-2.007, and a ratio of the second cylindrical hub portion outer diameter to the hub bore diameter is 2.051-2.063.

Abstract: An air cycle machine includes turbine and compressor housings respectively having a turbine and a compressor. An insulator seal plate is fastened between the turbine and compressor housings. The insulator seal plate includes a bore. A seal has an outer diameter that engages the bore. The seal also includes an inner diameter provided between lateral sides defining a first width. The inner diameter provides a seal and configured to engage a rotating surface. The outer diameter to the inner diameter provides a first ratio of 1.30-1.31. The inner diameter to the first width provides a second ratio of 1.59-1.61. A rotor shaft is disposed in the seal and includes knife edges extending from the rotor shaft to the seal land. The rotor shaft supports the turbine and the compressor.

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 section with a multiple turbine vanes which each extend for a vane height H, a throat width W defined between each of the multiple of turbine vanes, wherein a ratio W/H is 0.745-0.769.

Abstract: A thrust bearing shaft has a radially enlarged thrust disk to be mounted between two static housing surfaces in an air cycle machine. A first portion of the thrust bearing shaft extends from a first face of the thrust disk. A second portion extends from a second opposed face of the thrust disk. The second portion has sealing ribs and six holes. The sealing ribs are spaced closer to the thrust disk than are the holes. A ratio of a distance from an end of the second portion to a center of the holes compared to a distance from the end of the second portion to the second face of the thrust disk is between 0.20 and 0.22. In addition, an air cycle machine incorporating the thrust bearing shaft, and a method of assembling the thrust bearing shaft into an air cycle machine are disclosed.

Abstract: An air cycle machine including a housing with a compressor housing portion and a turbine housing portion secured to one another by fasteners. The compressor and turbine housing portions each provide a surface. An insulator plate is provided between and engages the surfaces. The fasteners extend through circumferentially arranged holes in the insulator plate. The insulator plate has an axial width, an inner diameter and an outer diameter. The outer diameter to the inner diameter provides a first ratio of 1.19-1.21, and the inner diameter to the width provides a second ratio of 53-59. In one example, the insulator plate is a composite structure constructed from 9-12 carbon fiber laminations with each layer having directional carbon fibers oriented transversely relative to the carbon fibers of an adjacent layer.

Abstract: A variable diffuser for a rotating machine includes a multiple of diffuser vanes mounted to a drive ring. The multiple of diffuser vanes are movable in unison between a maximum flow position and a minimum flow position in response to rotation of a crank to rotate the drive ring about a centerline through a link arm.

Abstract: A ram air fan assembly includes a ram air fan disposed at a fan inlet and a ram air fan motor operably connected to the ram air fan. A blower is operably connected to the ram air fan and is configured to redirect a cooling flow across the ram air fan motor from a substantially axially directed flow to a substantially radially directed flow thereby increasing the cooling flow across the ram air fan motor. A method of cooling a ram air fan assembly includes urging a cooling flow toward the ram air fan motor and is directed across the ram air fan motor thus removing thermal energy from the ram air fan motor. The cooling flow proceeds across a blower operably connected to the ram air fan motor, thus directing the cooling flow substantially radially outwardly toward the fan inlet.

Abstract: An improved staggered seal assembly uses a static element and a rotating element to create a seal. The static element surrounds the rotating element and has at least one fin. The rotating element has at least one long fin and a set of shorter fins. A third component has a staggered fin. The fins create a leakage flow path which throttles the leakage across the seal from a high pressure zone into a low pressure zone.

Abstract: Disclosed is a compressor (12) for a refrigeration system (10) including a housing (30) and at least one compressor impeller (24, 26) located in the housing (30) capable of compressing a refrigerant flow (14) through the compressor (12). At least one refrigerant pathway (44, 62) is located inboard of an outer surface (48) of the housing (30) and extends from a first compressor impeller (24). Further disclosed is a refrigeration system (10) including a compressor (12) having at least one refrigerant pathway (44, 62) located inboard of an outer surface (48) of the housing (36) and extending from a first compressor impeller (24) of at least one compressor impeller (24, 26). Further disclosed is a method of flowing refrigerant through a compressor (12).

Abstract: A compressor rotor compresses air and delivers the compressed air to a downstream inlet and across a turbine rotor. A shaft rotates with the turbine rotor and the compressor rotor. The shaft is hollow with an inner bore and an outer periphery. At least one journal bearing supports a portion of the shaft, and has an inner bore spaced from the outer periphery of the shaft. A cooling air path is provided between the shaft outer periphery and the bearing inner periphery, and along a length of the bearing to at least one connection hole. The connection hole provides cooling air from an outer periphery of the shaft to the inner bore of the shaft. In a separate feature, a shaft for use in an air supply machine includes a hollow interior, with such a connection hole.