A high heat dissipation, integrated ducted fan electric propulsion system

Abstract

The present invention discloses a high heat dissipation, integrated ducted fan electric propulsion system, which belongs to the technical field of ducted fans, including a motor controller, a motor, a motor front bearing, a motor rear bearing, a front fairing, a rear fairing, an integrated fan shaft formed by fan blades and a motor shaft, and an integrated nacelle motor housing formed by a motor housing, a ducted nacelle and a plurality of ducted stator blades; a cooling device is installed on the motor housing and the motor controller; the cooling device includes a cooling water channel and a water cooling cavity; a cooling water channel is provided on the motor housing; a water cooling cavity is provided on the motor controller, and the cooling water channel is connected to the water cooling cavity; the front fairing is connected to the left end of the integrated fan shaft, and the rear fairing is connected to the right end of the motor controller. The present invention has high integration, high power density by reducing connecting components and reducing volume and weight; high system reliability; high system cooling efficiency; strong power level compatibility and scalability.

Description

Technical Field

[0001] The present invention relates to the technical field of ducted fans, and in particular to a high heat dissipation, integrated ducted fan electric propulsion system. Background Art

[0002] For the electric propulsion systems of electric / hybrid aircraft, conventional aircraft (CTOL), short take-off and landing aircraft (STOL) and vertical take-off and landing aircraft (EVTOL), the electric ducted fan propulsion system is the most preferred electric propulsion system solution in the future electric aviation field due to its high efficiency and energy saving, compact structure and low noise.

[0003] The core components of the electric ducted fan propulsion system include the fan, drive motor, motor controller, duct (nacelle), guide vanes and center body hub. These components work together to accelerate the airflow and generate thrust. Among them, the fan is a key component that accelerates the airflow through rotation to generate thrust; the duct is similar to an airfoil duct, which not only guides the airflow, but also plays a role in gathering and diffusing the airflow.

[0004] The ducted fan system in the prior art mainly has the following technical problems:

[0005] 1) There are many parts and many connecting components between different parts. The connections are complex and have low reliability, resulting in a high probability of failure. In addition, a cooling system is usually required to cool the motor, which increases the weight.

[0006] 2) Low integration, large size and heavy weight.

[0007] 3) Poor power scalability and compatibility in different application scenarios. Limited by the heat dissipation conditions of the electric propulsion system, the electric ducted fan propulsion system of the same design model can only be used in a narrow power level and cannot meet the needs of different power levels and application scenarios.

[0008] 4) Low system cooling efficiency. When an aircraft flies at high altitude, the speed relative to the air is very high (usually 20-100m / s). The motor is installed inside the duct nacelle, and high-speed forced air cooling cannot be effectively utilized; the motor controller is installed in the fuselage or wing, separated from the motor, and connected in the middle by a cooling pipe, the system cooling efficiency is low and the loss is large; the motor and controller are separated, which does not effectively benefit the most efficient heat dissipation components (fans and nacelles) of the duct; because the electric propulsion system generates heat when in use, it is usually necessary to design additional heat dissipation components for cooling. When additional heat dissipation structures are added, additional structural weight will be added, and the increased surface area of ​​the heat dissipation components will cause aerodynamic losses, increase resistance, and reduce system efficiency.

[0009] Based on this, the present invention designs a high heat dissipation, integrated ducted fan electric propulsion system to solve the above problems. Summary of the invention

[0010] In view of the above-mentioned shortcomings of the prior art, the present invention provides a high heat dissipation, integrated ducted fan electric propulsion system.

[0011] To achieve the above objectives, the present invention is implemented through the following technical solutions:

[0012] A high heat dissipation, integrated ducted fan electric propulsion system, comprising a motor controller, a motor, a motor front bearing, a motor rear bearing, a front fairing, a rear fairing, an integrated fan shaft formed by fan blades and a motor shaft, and an integrated nacelle motor housing formed by a motor housing, a ducted nacelle and a plurality of ducted stator blades; the ducted stator blades are located between the ducted nacelle and the motor housing; a cooling device is installed on the motor housing and the motor controller; the cooling device comprises a cooling water channel and a water cooling chamber; a cooling water channel is provided on the motor housing; a water cooling chamber is provided on the motor controller, and the cooling water channel is connected to the water cooling chamber; the motor is rotatably connected to the motor shaft through the motor front bearing and the motor rear bearing; the motor controller is installed at the right end of the motor; the front fairing is connected to the left end of the integrated fan shaft, and the rear fairing is connected to the right end of the motor controller.

[0013] Furthermore, the motor includes a motor shaft, a motor rotor, a motor stator winding, a motor housing, a motor front cover, and a motor rear cover; the motor stator winding is fixedly connected to the inside of the motor housing, and the motor front cover and the motor rear cover are respectively fixedly installed on the left and right sides of the motor housing; the upper and lower ends of the right side of the motor rear cover are respectively fixedly connected with a connecting pipe and a water outlet, and the two ends of the cooling water channel are respectively connected to one end of the connecting pipe and the water outlet.

[0014] Furthermore, the housing of the motor controller adopts a packaged cylindrical shell, the outer diameter of the cylindrical shell is the same as the outer diameter of the motor housing, and the cylindrical shell is fixedly mounted on the outer wall of the rear end cover of the motor.

[0015] Furthermore, a water cooling chamber is provided inside the cylindrical shell, and two ends of the water cooling chamber are respectively connected with a water inlet and the other end of the connecting pipe, and the water inlet is fixedly installed at the lower right end of the cylindrical shell.

[0016] Furthermore, the front end cover of the motor is rotatably connected to the motor shaft through the front bearing of the motor, and the rear end cover of the motor is rotatably connected to the motor shaft through the rear bearing of the motor; the motor rotor is fixedly connected to the motor shaft.

[0017] Furthermore, the front fairing is fixedly connected to the left end of the fan blade by fastening screws, and the rear fairing is fixedly connected to the right end of the cylindrical shell by fastening screws.

[0018] Furthermore, the integrated fan shaft is made of titanium alloy or aluminum alloy;

[0019] The integrated nacelle motor housing is made of aluminum alloy or magnesium alloy.

[0020] Furthermore, the duct stator blades adopt a thin-walled support sheet structure.

[0021] Furthermore, the motor rotor and the motor shaft are fixedly connected by heat-insertion interference fit.

[0022] Furthermore, the motor stator winding is fixedly connected to the motor housing by interference fit through processes such as hot embedding.

[0023] Compared with the prior art, the present invention has the following beneficial effects: 1) High integration, by reducing connecting components and reducing volume and weight, the power density is high; the fan blades and motor shaft are designed and manufactured in an integrated manner, the motor housing, the duct nacelle and multiple sets of duct stators are designed and manufactured in an integrated manner, the motor controller and the motor are designed in an integrated manner, and the cooling water channel is integrated internally. Through the above three integrated design schemes, the present invention effectively reduces the connecting components, and due to the integrated design, the parts can be effectively reduced in weight and volume, and the product has a high power density.

[0024] 2) High system reliability; simple structure, reduced parts and components, and low probability of system failure; through three integrated design schemes, due to the integrated design of parts, the present invention effectively reduces the failure risks caused by connecting components, parts themselves and fastening connections between different parts, and the system is simplified, thereby reducing the probability of failure.

[0025] 3) High system cooling efficiency; the motor and motor controller can use the same size to output higher power and high power density; by integrating the fan blades and motor shaft and using metal materials with good thermal conductivity such as aluminum alloy / titanium alloy, the fan blades can be effectively used as excellent heat sinks to dissipate heat from the motor shaft and the motor rotor, motor front bearing, and motor rear bearing thereon; by integrating the motor housing, duct nacelle, and multiple sets of ducted stator blades and using metal materials with good thermal conductivity such as aluminum alloy / magnesium alloy, the duct nacelle and ducted stator blades can be effectively used as excellent heat sinks to dissipate heat from the motor stator winding; by integrating the cooling water channels of the motor and motor controller, the number of connecting intermediate pipes and parts can be reduced, heat loss can be reduced, and cooling efficiency can be improved.

[0026] 4) Strong power level compatibility and scalability; the present invention adopts a hybrid cooling method of high-efficiency air cooling + water cooling, and the cooling method of the product can be adjusted to make the product of the present invention applicable to a wider power level; in the lower power application range of the motor (less than 80KW), the present invention can use a high-efficiency air cooling design solution alone to meet product application requirements at a low cost; in the higher power application range of the motor (80-250KW), the present invention can use a hybrid cooling (high-efficiency air cooling + integrated water cooling) solution to meet application requirements under high-power conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the prior art descriptions are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention, and for ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0028] Figure 1 A cross-sectional view of a high heat dissipation, integrated ducted fan electric propulsion system of the present invention;

[0029] Figure 2 It is a structural diagram of the integrated fan shaft formed by the fan blades and the motor shaft in the high heat dissipation, integrated ducted fan electric propulsion system of the present invention after the motor rotor, the motor front bearing and the motor rear bearing are assembled;

[0030] Figure 3 A cross-sectional view of the integrated fan shaft after the motor rotor, the motor front bearing, and the motor rear bearing are assembled;

[0031] Figure 4 A cross-sectional view of the integrated fan shaft after the motor front end cover, motor rotor, motor front bearing, and motor rear bearing are assembled;

[0032] Figure 5 A cross-sectional view of an integrated nacelle motor housing formed integrally by a motor housing, a ducted nacelle and a plurality of ducted stator blades in a high heat dissipation, integrated ducted fan electric propulsion system of the present invention;

[0033] Figure 6 A cross-sectional view of the integrated nacelle motor housing after the motor stator winding is assembled;

[0034] Figure 7 A cross-sectional view of the integrated nacelle motor housing after the motor stator winding and the motor rear end cover are assembled;

[0035] Figure 8 It is the structural diagram of the motor controller;

[0036] Fig. 9It is a schematic diagram of the assembly of the high heat dissipation, integrated ducted fan electric propulsion system of the present invention.

[0037] The numbers in the figure represent:

[0038] 1. Fan blades 2. Motor shaft 3. Motor rotor 4. Motor stator winding 5. Motor housing 6. Motor front cover 7. Motor rear cover 8. Motor front bearing 9. Motor rear bearing 10. Cylindrical housing 11. Duct nacelle 12. Motor controller 13. Front fairing 14. Rear fairing 15. Cooling water channel 16. Connecting pipe 17. Water outlet 18. Water inlet 19. Duct stator blades 20. Water cooling chamber 21. Integrated fan shaft 22. Integrated nacelle motor housing. DETAILED DESCRIPTION

[0039] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0040] In the following description, the terms “left”, “right”, “front”, “back”, “up” and “down” are used to refer to Figure 1 The viewing direction is oriented.

[0041] Embodiment 1: In some embodiments, please refer to the drawings of the specification Figure 1-Figure 9 , a high heat dissipation, integrated ducted fan electric propulsion system, comprising a motor controller 12, a motor, a motor front bearing 8, a motor rear bearing 9, a front fairing 13, a rear fairing 14, an integrated fan shaft 21 formed by a fan blade 1 and a motor shaft 2, and an integrated nacelle motor housing 22 formed by a motor housing 5, a ducted nacelle 11 and a plurality of ducted stator blades 19;

[0042] The integrated fan shaft 21 is made of titanium alloy or aluminum alloy;

[0043] The integrated nacelle motor housing 22 is made of aluminum alloy or magnesium alloy;

[0044] Air cooling scheme 1 of the present invention: adopting an integrated fan shaft 21 with an integrated structure can reduce the fastening and connecting parts between the traditional split-design fan and the motor shaft; at the same time, since the electric aircraft has a very high convection cooling speed (usually in the range of 20-100m / s) relative to the air during high-speed flight, the fan blade 1 is a natural and excellent heat sink. After the fan blade 1 and the motor shaft 2 are designed and manufactured in an integrated manner, the fan blade 1 can be efficiently used as a heat sink to directly dissipate the heat from the motor shaft 2;

[0045] At the same time, after the integrated fan shaft 21 is assembled into a rotor assembly, the integrated fan shaft 21 can be used as a heat sink to dissipate heat from the motor rotor 3 and the motor bearings (the motor front bearing 8 and the motor rear bearing 9).

[0046] The duct stator blades 19 are located between the duct nacelle 11 and the motor housing 5;

[0047] The conventional split-design motor has a separate housing, and the housing and the duct vanes 19 need to be connected by a connecting structure and fasteners. The present invention integrates the motor housing 5, the duct nacelle 11 and the duct vanes 19 into an integrated design, which can effectively reduce the intermediate connecting structures and parts, and at the same time can reduce the mass and improve the overall strength of the duct.

[0048] Air cooling scheme 2 of the present invention: Since the electric aircraft has a very high convection cooling speed (usually in the range of 20-100m / s) relative to the air during high-speed flight, the ducted nacelle 11 is a natural heat sink. The ducted stator blades 19 are located in the ducted nacelle 11, behind the fan blades 1. Due to the high-speed rotation of the fan blades 1, the high-speed airflow is blown to the ducted stator blades 19, which are excellent heat sinks. After the motor housing 5, the ducted nacelle 11 and a plurality of ducted stator blades 19 are integrated and manufactured, the ducted nacelle 11 and the ducted stator blades 19 can be efficiently used as heat sinks to directly dissipate the heat from the motor housing 5.

[0049] The motor housing 5 and the motor controller 12 are provided with cooling devices;

[0050] The cooling device comprises a cooling water channel 15, a water outlet 17, a water inlet 18 and a water cooling chamber 20;

[0051] The motor housing 5 is provided with a cooling water channel 15;

[0052] The motor includes a motor shaft 2, a motor rotor 3, a motor stator winding 4, a motor housing 5, a motor front cover 6, and a motor rear cover 7; the motor stator winding 4 is fixedly connected to the inside of the motor housing 5, and preferably, the motor stator winding 4 is fixedly connected to the motor housing 5 by interference fit through a process such as hot embedding; the motor front cover 6 and the motor rear cover 7 are respectively fixedly installed on the left and right sides of the motor housing 5; the upper and lower ends of the right side of the motor rear cover 7 are respectively fixedly connected with a connecting pipe 16 and a water outlet 17, and the two ends of the cooling water channel 15 are respectively connected with one end of the connecting pipe 16 and the water outlet 17;

[0053] When the motor stator winding 4 is heated, the heat can be dissipated by the air-cooled radiator formed by the duct nacelle 11 and the duct stator blades 19, or by the cooling water channel 15 built into the motor housing 5;

[0054] The outer shell of the motor controller 12 adopts an encapsulated cylindrical shell 10, the outer diameter of the cylindrical shell 10 is the same as or close to the outer diameter of the motor shell, and the cylindrical shell 10 is fixedly mounted on the outer wall of the rear end cover 7 of the motor; preferably, the cylindrical shell 10 is fastened to the rear end cover 7 of the motor by three fixing screws.

[0055] Different from the traditional design where the motor and motor controller are separated and the three-phase terminals of the motor and the three-phase terminals of the motor controller need high-voltage connectors and high-voltage wiring harnesses to connect, the present invention integrates the motor controller 12 with the motor, and the three-phase terminals of the motor U, V, W and the three-phase terminals of the motor controller 12 are directly connected through copper bars inside the cavity of the motor controller 12. This effectively reduces the number of connecting parts, simplifies the connection structure, and is conducive to cost reduction and weight reduction.

[0056] The cylindrical shell 10 has a water cooling chamber 20 formed inside, and the two ends of the water cooling chamber 20 are respectively connected to the water inlet 18 and the other end of the connecting pipe 16. The water inlet 18 is fixedly mounted at the lower right end of the cylindrical shell 10.

[0057] The water cooling solution of the present invention: the cooling water path of the integrated cooling water channel is: water inlet 18 - water cooling chamber 20 - connecting pipe 16 - cooling water channel 15 - water outlet 17;

[0058] Different from the separate design of the motor and the motor controller, the water inlet of the motor and the water outlet of the motor controller need to be connected by nozzle parts, water pipes, clamps and other parts; the present invention integrates the cooling water channel internally, and the water inlet of the motor and the water outlet of the motor controller are directly connected in the controller cavity through a reasonably designed matching structure. It reduces the number of connecting parts and simplifies the connection structure, which is conducive to cost reduction and weight reduction;

[0059] The integrated fan shaft 21, the motor front end cover 6, the motor front bearing 8, the motor rear bearing 9, and the motor rotor 3 are assembled into a rotor assembly; the motor front end cover 6 is rotatably connected to the motor shaft 2 through the motor front bearing 8, and the motor rear end cover 7 is rotatably connected to the motor shaft 2 through the motor rear bearing 9; the motor rotor 3 is fixedly connected to the motor shaft 2;

[0060] The front fairing 13 is fixedly connected to the left end of the fan blade 1 by fastening screws, and the rear fairing 14 is fixedly connected to the right end of the cylindrical shell 10 by fastening screws.

[0061] The present invention has the following technical effects:

[0062] 1) High integration, by reducing the number of connecting parts, reducing the volume and weight, the power density is high; the fan blades and the motor shaft are designed and manufactured in an integrated manner, the motor housing, the duct nacelle and multiple sets of duct stators are designed and manufactured in an integrated manner, the motor controller and the motor are designed in an integrated manner, and the cooling water channel is integrated internally. Through the above three integrated design schemes, the present invention effectively reduces the number of connecting parts, and due to the integrated design, the parts can effectively reduce weight and volume, and the product has a high power density.

[0063] 2) High system reliability; simple structure, reduced parts and components, and low probability of system failure; through three integrated design schemes, due to the integrated design of parts, the present invention effectively reduces the failure risks caused by connecting components, parts themselves and fastening connections between different parts, and the system is simplified, thereby reducing the probability of failure.

[0064] 3) The system has high cooling efficiency; the motor and the motor controller 12 can use the same size to output higher power and have high power density; by integrating the fan blades 1 and the motor shaft 2 and using metal materials with good thermal conductivity such as aluminum alloy / titanium alloy, the fan blades 1 can be effectively used as an excellent heat sink to dissipate heat from the motor shaft 2 and the motor rotor 3, the motor front bearing 8, and the motor rear bearing 9 thereon; by integrating the motor housing 5, the duct nacelle 11 and multiple groups of duct stator blades 19 and using metal materials with good thermal conductivity such as aluminum alloy / magnesium alloy, the duct nacelle 11 and the duct stator blades 19 can be effectively used as excellent heat sinks to dissipate heat from the motor stator winding 4; by integrating the cooling water channels of the motor and the motor controller 12, the number of connecting intermediate pipes and parts can be reduced, heat loss can be reduced, and cooling efficiency can be improved.

[0065] 4) Strong power level compatibility and scalability; the present invention adopts a hybrid cooling method of high-efficiency air cooling + water cooling, and the cooling method of the product can be adjusted to make the product of the present invention applicable to a wider power level; in the lower power application range of the motor (less than 80KW), the present invention can use a high-efficiency air cooling design solution alone to meet product application requirements at a low cost; in the higher power application range of the motor (80-250KW), the present invention can use a hybrid cooling (high-efficiency air cooling + integrated water cooling) solution to meet application requirements under high-power conditions.

[0066] Embodiment 2: In some embodiments, Figure 1-Figure 9 As shown, as a preferred embodiment of the present invention, preferably, the duct stator blade 19 adopts a thin-walled support sheet structure.

[0067] Embodiment 3: In some embodiments, Figure 1-Figure 9 As shown, as a preferred embodiment of the present invention, preferably, the motor rotor 3 and the motor shaft 2 are fixedly connected by heat-insertion interference fit.

[0068] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. Such modifications or replacements will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A high heat dissipation, integrated ducted fan electric propulsion system, characterized in that: The invention comprises a motor controller (12), a motor, a motor front bearing (8), a motor rear bearing (9), a front fairing (13), a rear fairing (14), an integrated fan shaft (21) formed integrally of a fan blade (1) and a motor shaft (2), and an integrated nacelle motor housing (22) formed integrally of a motor housing (5), a ducted nacelle (11) and a plurality of ducted stator blades (19); the ducted stator blades (19) are located between the ducted nacelle (11) and the motor housing (5); a cooling device is installed on the motor housing (5) and the motor controller (12); the cooling device comprises a cooling water channel (15) and a water cooling chamber (20); the motor A cooling water channel (15) is provided on the machine housing (5); a water cooling chamber (20) is provided on the motor controller (12), and the cooling water channel (15) is communicated with the water cooling chamber (20); a motor front end cover (6) and a motor rear end cover (7) are provided at both ends of the motor, respectively; the motor front end cover (6) is rotatably connected to the motor shaft (2) via a motor front bearing (8), and the motor rear end cover (7) is rotatably connected to the motor shaft (2) via a motor rear bearing (9); the motor controller (12) is mounted on the right end of the motor; the front fairing (13) is connected to the left end of the integrated fan shaft (21), and the rear fairing (14) is connected to the right end of the motor controller (12).

2. The high heat dissipation, integrated ducted fan electric propulsion system according to claim 1, characterized in that: The motor comprises a motor shaft (2), a motor rotor (3), a motor stator winding (4), a motor housing (5), a motor front end cover (6), and a motor rear end cover (7); the motor stator winding (4) is fixedly connected to the inside of the motor housing (5); the motor front end cover (6) and the motor rear end cover (7) are respectively fixedly mounted on the left and right sides of the motor housing (5); the upper and lower ends of the right side of the motor rear end cover (7) are respectively fixedly connected to a connecting pipe (16) and a water outlet (17); and the two ends of the cooling water channel (15) are respectively connected to one end of the connecting pipe (16) and the water outlet (17).

3. The high heat dissipation, integrated ducted fan electric propulsion system according to claim 2, characterized in that: The outer shell of the motor controller (12) is a sealed cylindrical shell (10), the outer diameter of the cylindrical shell (10) is the same as the outer diameter of the motor shell, and the cylindrical shell (10) is fixedly mounted on the outer wall of the rear end cover (7) of the motor.

4. The high heat dissipation, integrated ducted fan electric propulsion system according to claim 3, characterized in that: A water cooling chamber (20) is provided inside the cylindrical shell (10), and two ends of the water cooling chamber (20) are respectively connected to the water inlet (18) and the other end of the connecting pipe (16), and the water inlet (18) is fixedly mounted on the lower right end of the cylindrical shell (10).

5. The high heat dissipation, integrated ducted fan electric propulsion system according to claim 4, characterized in that: The motor rotor (3) is fixedly connected to the motor shaft (2).

6. The high heat dissipation, integrated ducted fan electric propulsion system according to claim 5, characterized in that: The front fairing (13) is fixedly connected to the left end of the fan blade (1) by means of fastening screws, and the rear fairing (14) is fixedly connected to the right end of the cylindrical shell (10) by means of fastening screws.

7. The high heat dissipation, integrated ducted fan electric propulsion system according to claim 6, characterized in that: The integrated fan shaft (21) is made of titanium alloy or aluminum alloy; The integrated nacelle motor housing (22) is made of aluminum alloy or magnesium alloy.

8. The high heat dissipation, integrated ducted fan electric propulsion system according to any one of claims 1 to 7, characterized in that: The duct stator blade (19) adopts a thin-walled support sheet structure.

9. The high heat dissipation, integrated ducted fan electric propulsion system according to claim 2, characterized in that: The motor rotor (3) and the motor shaft (2) are fixedly connected by means of heat-insertion interference fit.

10. The high heat dissipation, integrated ducted fan electric propulsion system according to claim 2, characterized in that: The motor stator winding (4) is fixedly connected to the motor housing (5) by interference fit through a process such as hot embedding.

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