A high power density propulsion device, assembly, and aircraft engine

Abstract

The application provides a high-power-density propulsion device, assembly and aero-engine, and relates to the field of aero-engine.The propulsion device comprises a transmission shaft, a sun gear is sleeved on the transmission shaft, a plurality of propulsion units are distributed around the transmission shaft, the propulsion unit comprises an outer gear ring, the outer gear ring rotates under the drive of the propulsion unit, an inner gear ring is arranged around the plurality of propulsion units and the transmission shaft, the outer gear rings on the plurality of propulsion units are meshed with the sun gear and the inner gear ring at the same time, so as to drive the transmission shaft and the inner gear ring, and the inner gear ring drives a fan blade disc to rotate.The strict performance index requirement is met under the demand of limited space and limited weight.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of aero-engines, in particular to a high-power-density propulsion device, an assembly and an aero-engine. BACKGROUND

[0002] The megawatt electric drive assembly is the "heart" of a high-power electric aircraft, and its performance directly affects the safety, economy, environmental protection and comfort of the aircraft. Whether pure electric or hybrid architecture, a propulsion unit is needed.

[0003] It is crucial to master the core technology of electric machine design and develop new aircraft power industry layout represented by electric drive. The weight and size of each component in the aircraft electric propulsion assembly have very strict requirements, especially for aircraft electric machines. It is difficult to replace traditional gas turbines due to insufficient power density. High-power-density propulsion unit design is a key technology in electric machine design. SUMMARY

[0004] The purpose of the present application is at least to provide a high-power-density propulsion device under the premise of the demand for high power density of an aviation propulsion electric machine, which meets the strict performance index requirements under the demand of limited space and limited weight.

[0005] The following gives a brief summary of one or more aspects to provide a basic understanding of these aspects. This summary is not an exhaustive overview of all contemplated aspects, and neither is it intended to identify key or critical elements of all aspects nor to delineate the scope of any or all aspects. Its only purpose is to give some concepts of one or more aspects in a simplified form as a prelude to the more detailed description given later.

[0006] One of the embodiments of the present application provides a high-power-density propulsion device, which comprises:

[0007] A transmission shaft, a sun gear is sleeved on the transmission shaft.

[0008] A plurality of propulsion units, the plurality of propulsion units are distributed around the transmission shaft, and the propulsion unit comprises an outer gear ring, which rotates under the drive of the propulsion unit.

[0009] An inner gear ring, the inner gear ring is arranged around the plurality of propulsion units and the transmission shaft, and the outer gear ring on the plurality of propulsion units is engaged with the sun gear and the inner gear ring at the same time to drive the transmission shaft and the inner gear ring.

[0010] The inner gear ring drives the fan disc to rotate.

[0011] One of the embodiments of the present application provides a high-power-density propulsion device, which comprises:

[0012] A transmission shaft, a sun gear is sleeved on the transmission shaft.

[0013] Multiple propulsion units are distributed around the drive shaft. Each propulsion unit includes an external gear ring, which rotates under the drive of the propulsion units.

[0014] An internal gear ring surrounds multiple propulsion units and a drive shaft. External gear rings on multiple propulsion units simultaneously mesh with the sun gear and the internal gear ring to drive the drive shaft and the internal gear ring.

[0015] The drive shaft drives the fan impeller to rotate.

[0016] One embodiment of the present invention provides a high power density propulsion device, the propulsion device comprising:

[0017] A drive shaft, on which a sun gear is mounted.

[0018] The propulsion motor is connected to the drive shaft, which rotates under the drive of the propulsion motor.

[0019] Multiple propulsion units are distributed around the drive shaft. Each propulsion unit includes an external gear ring, which rotates under the drive of the propulsion unit.

[0020] An internal gear ring surrounds multiple propulsion units and a drive shaft. The external gear rings on the multiple propulsion units mesh with the sun gear and the internal gear ring simultaneously. The propulsion motor and the multiple propulsion units work together to drive the internal gear ring to rotate.

[0021] The internal gear ring drives the fan impeller to rotate.

[0022] In some embodiments, the high power density propulsion device includes a planetary carrier for fixing the stator portion of the propulsion unit, and the planetary carrier is connected to the rotor portion of the propulsion unit via bearings.

[0023] In some embodiments, the propulsion unit includes a slotless permanent magnet synchronous motor based on a Halbach array, with an external gear ring fitted on the outside of the motor.

[0024] In some embodiments, the propulsion device includes 2 to 8 slotless permanent magnet synchronous motors.

[0025] In some embodiments, the high power density propulsion device includes an outer rotor, which is sleeved on the outside of the inner gear ring, and the center of the outer rotor is connected to the fan blade disk through an output shaft to drive the fan blade disk to rotate.

[0026] In some embodiments, the high power density propulsion device includes an energy storage unit that is poweredly connected to a drive shaft and is used to convert and store the kinetic energy generated by the drive shaft.

[0027] One embodiment of the present invention provides a high power density propulsion assembly, which includes the high power density propulsion device of the above embodiment and a coordination controller.

[0028] The propulsion unit includes a unit controller, which can monitor the operational status data of the propulsion unit.

[0029] The coordination controller is connected to the unit controller via signals. The coordination controller is used to control the propulsion unit based on the operating status data.

[0030] One embodiment of the present invention provides an aero-engine, including the high power density propulsion device or the high power density propulsion assembly of the above embodiments.

[0031] The high-power-density propulsion device of this invention features a rotor unit highly integrated with gears, enabling both speed regulation and direct coupling of the output torque from multiple propulsion units to a single port. This port is directly drive-compatible with propellers, ducted fans, and other similar devices, making it suitable for low-speed, high-torque applications. Furthermore, the propulsion unit is integrated into a planetary gearbox, allowing for an ultra-short shaft design and further reducing the weight of the high-power-density propulsion device.

[0032] The present invention relates to a high power density propulsion device, in which the rotational speed of the propulsion unit is controlled within 20,000 rpm. This rotational speed can be achieved by matching the radius of the external gear ring with the low-pressure shaft to a high speed. This high-speed design contributes to increasing the power-to-weight ratio of the motor. Furthermore, the research on a single ultra-high power, high-speed megawatt-class aerospace motor and its gearbox is transformed into the research on multiple smaller power propulsion units, resulting in higher maturity and lower cost.

[0033] The high-power-density propulsion device involved in this invention is applicable to future megawatt-class commercial aviation electric propulsion systems. This is because the power of high-bypass turbofan engines is primarily generated by the fan's outer bypass duct. In the process of electrification, directly replacing components such as the low-pressure shaft, high-pressure shaft, combustion chamber, and turbine with megawatt-class electric propulsion devices is an inevitable development trend for future high-bypass turbofan engines. The high-power-density propulsion device can be applied to megawatt-class aviation electric propulsion systems, megawatt-class low-speed, high-torque wind power generation systems, hundreds-kilowatt-class propulsion motors for low-altitude economic small and medium-sized aircraft (eVTOL, eCTOL, UAM), tens-kilowatt-class hub motor assemblies for new energy vehicles, and high-compact shutdown motor assemblies for robots, among other applications, demonstrating a wide range of potential applications. Attached Figure Description

[0034] The above-described features and advantages of the present invention will be better understood after reading the following detailed description of embodiments of the present disclosure in conjunction with the accompanying drawings. In the drawings, components are not necessarily drawn to scale, and components having similar related properties or features may have the same or similar reference numerals. Wherein:

[0035] Figure 1This is a schematic diagram of the internal structure of a high power density propulsion device according to some embodiments;

[0036] Figure 2 This is a schematic diagram showing the connection between a high power density propulsion device and a fan, according to some embodiments;

[0037] Figure 3 This is a structural schematic diagram of a high power density propulsion device according to some embodiments;

[0038] Figure 4 This is a side view of a high power density propulsion device according to some embodiments;

[0039] Figure 5 This is a three-dimensional diagram of the propulsion unit shown in some embodiments;

[0040] Figure 6 This is a top view of the propulsion unit according to some embodiments;

[0041] Figure 7 This is a schematic diagram of a high power density propulsion assembly as shown in some embodiments. Detailed Implementation

[0042] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. It should be noted that the aspects described below with reference to the accompanying drawings and specific embodiments are merely exemplary and should not be construed as limiting the scope of protection of the present invention in any way.

[0043] It should be understood that the terms “system,” “device,” “unit,” and / or “module” used herein are one method of distinguishing different components, elements, parts, sections, or assemblies at different levels. However, if other words can achieve the same purpose, they may be replaced by other expressions.

[0044] It is understood that the technical terms that may be used in the description of this specification, such as “center,” “longitudinal,” “lateral,” “front,” “rear,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” and “outer,” indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the implementation method and do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the scope of protection of the invention.

[0045] It should be noted that the use of terms such as "first" and "second" to define features in this document is merely for the purpose of distinguishing the corresponding features. Unless otherwise stated, these terms have no special meaning and should not be construed as limiting the scope of protection of this invention. As shown in this specification and claims, the terms "a," "an," "an," and / or "the" do not specifically refer to the singular and may also include the plural, unless the context clearly indicates otherwise. Generally, the terms "comprising" and "including" only indicate the inclusion of explicitly identified steps and elements, and these steps and elements do not constitute an exclusive list; the method or apparatus may also include other steps or elements.

[0046] In the description of this specification, it should also be noted that, unless otherwise expressly specified or limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, an integral connection, or a detachable connection; a mechanical connection or an electrical connection; a direct connection or an indirect connection through an intermediate medium, or a connection within two components, etc. Those skilled in the art can understand the specific meaning of the above terms in this specification according to the specific circumstances.

[0047] Figure 1 This is a schematic diagram of the internal structure of a high power density propulsion device according to some embodiments.

[0048] This specification provides an embodiment of a high power density propulsion device, such as... Figure 1 As shown, the propulsion device 1 includes a drive shaft 11, a propulsion unit 12, and an internal gear ring 13.

[0049] The drive shaft 11 is located at the center of the propulsion device 1. A sun gear 111 is mounted on the drive shaft 11 and is fixed relative to the drive shaft 11.

[0050] There are multiple propulsion units 12, which are distributed around the drive shaft 11. In some embodiments, two to eight, or even more or fewer, propulsion units 12 are provided, depending on the actual power requirements. Figure 1 The three propulsion units 12 shown are for illustrative purposes only. For ease of explanation, this specification will continue to describe the invention using three propulsion units 12 as an example.

[0051] See Figure 1 The propulsion unit 12 is capable of outputting power, which provides the propulsion force for the entire propulsion device 1. The propulsion unit 12 includes an external gear ring 121, which rotates under the drive of the propulsion unit 12 to transmit the power of the propulsion unit 12 outward.

[0052] The internal gear ring 13 has a ring-shaped structure and surrounds multiple propulsion units 12 and the drive shaft 11. The internal gear ring 13 and the drive shaft 11 are coaxially arranged. Multiple propulsion units 12 are arranged between the internal gear ring 13 and the drive shaft 11. The external gear rings 121 on the multiple propulsion units 12 simultaneously mesh with the sun gear 111 and the internal gear ring 13.

[0053] Figure 2 This is a schematic diagram showing the connection between a high power density propulsion device and a fan, according to some embodiments.

[0054] In some embodiments, the rotation of multiple external gear rings 121 can simultaneously drive the sun gear 111 and the internal gear ring 13 to rotate, and the sun gear 111 drives the drive shaft 11 to rotate. When the external gear rings 121 simultaneously drive the sun gear 111 and the internal gear ring 13, the fan impeller 22 can be driven by either the drive shaft 11 or the internal gear ring 13, thereby driving the rotation of the fan blades 21. In some embodiments, the drive shaft 11 is connected to the fan impeller 22 to drive the fan blades 21 to rotate. (The following is a continuation of the previous paragraph.) Figures 3-4 This describes the structure by which the internal gear ring 13 drives the fan impeller 22 to rotate. The fan casing 23 encloses the propulsion device 1 and the entire fan assembly.

[0055] Traditional aircraft engines cause air pollution (CO2, NO) due to combustion. X Emissions will exacerbate global environmental pollution, and the electrification of aircraft engines is an inevitable trend in green development. This specification's embodiments transform the study of a single ultra-high-power, high-speed megawatt-class aircraft motor and its gearbox into a study of a bundled combination of multiple smaller-power propulsion units 12, with multiple propulsion units 12 providing power to the fan. The power-to-weight ratio of the propulsion unit 12 has reached at least 3 kW / kg, meeting the high power density requirements for replacing traditional gas turbines. In some embodiments, the power-to-weight ratio of the propulsion unit 12 has reached 3.8 kW / kg.

[0056] Figure 3 This is a structural schematic diagram of a high power density propulsion device according to some embodiments. Figure 4 This is a side view of a high power density propulsion device according to some embodiments.

[0057] like Figure 3 and Figure 4 As shown, the propulsion device 1 includes an outer rotor 14, which is divided into upper and lower sections (relative to the upper and lower sections). Figure 3The outer rotor 14 is fixed relative to the inner gear ring 13 and consists of two parts (the sun gear 111, the inner gear ring 13, and the propulsion unit 12). In some embodiments, the outer rotor 14 encloses the sun gear 111, the inner gear ring 13, and the propulsion unit 12. The outer rotor 14 rotates under the drive of the inner gear ring 13. An output shaft 141 extends outward from the center of the outer rotor 14. The output shaft 141 is connected to the fan impeller 22, and the outer rotor 14 is connected to the fan impeller 22 through the output shaft 141 to drive the fan impeller 22 to rotate. It should be understood that there is no connecting structure between the drive shaft 111 and the output shaft 141.

[0058] In some embodiments, such as Figure 4 As shown, the drive shaft 11 and the output shaft 141 extend outward from opposite sides of the outer rotor 14 in opposite directions.

[0059] In some embodiments, the propulsion unit 12 simultaneously drives the drive shaft 11 and the internal gear ring 13 to rotate. The drive shaft 11 is poweredly connected to the energy storage unit, which can convert the kinetic energy generated by the rotation of the drive shaft 11 into electrical energy for storage.

[0060] In some embodiments, the drive shaft 11 can also provide propulsion force to the propulsion device 1. The drive shaft 11 is connected to a propulsion motor or an energy storage unit. The drive shaft 11 rotates under the drive of the propulsion motor or the energy storage unit. At this time, the energy storage unit releases its stored electrical energy and converts it into the kinetic energy of the drive shaft 11's rotation. The drive shaft 11 and multiple propulsion units 12 jointly drive the internal gear ring 13 to rotate. This can improve the fault tolerance of the propulsion device 1. Even if there is damage or failure in the propulsion motor or propulsion unit 12, the propulsion device 1 can still operate normally with the joint operation of the remaining propulsion components.

[0061] In some embodiments, such as Figure 1 As shown, the high power density propulsion device 1 includes a planetary carrier 15, which is used to fix the stator part of the propulsion unit 12. The planetary carrier 15 is connected to the rotor part of the propulsion unit 12 through bearings.

[0062] In some embodiments, the propulsion unit 12 includes a slotless permanent magnet synchronous motor based on a Halbach array, with an external gear ring 121 fitted onto the outside of the rotor of the permanent magnet synchronous motor. Next, in conjunction with... Figures 5-6 Explain the structure of propulsion unit 12.

[0063] Figure 5 This is a three-dimensional diagram of the propulsion unit shown in some embodiments. Figure 6 This is a top view of the propulsion unit shown according to some embodiments.

[0064] like Figure 5 and Figure 6As shown, the rotor portion of the propulsion unit 12 includes Halbach permanent magnets 124. Halbach permanent magnets are currently a high magnetic load design, and the use of this material can further reduce the amount of permanent magnets used, thereby achieving the effect of lightweighting the propulsion unit 12.

[0065] In some embodiments, the rotor portion of the propulsion unit 12 further includes a housing 122 and a rotor yoke 123. The Halbach permanent magnet 124, rotor yoke 123, housing 122, and external gear ring 121 are arranged sequentially in a radially outward direction along the propulsion unit 12, i.e., the rotor yoke 123 covers the outside of the Halbach permanent magnet 124, the housing 122 covers the outside of the rotor yoke 123, and the external gear ring 121 covers the outside of the housing 122. Specifically, the rotor yoke 123 is fixed to the housing 122 by a winding technique, thus ensuring a tight fit between the rotor yoke 123 and the housing 122. By providing a protective structure consisting of the rotor yoke 123 and the housing 122 outside the Halbach permanent magnet 124, this protective structure is thin and has sufficient preload and containment effect, effectively preventing the catastrophic consequences of the rotor components inside flying off under high-speed rotation.

[0066] In some embodiments, the stator portion of the propulsion unit 12 adopts a slotless structure, that is, the permanent magnet synchronous motor of the propulsion unit 12 adopts an external rotor Halbach slotless topology. Specifically, the stator portion of the propulsion unit 12 includes a Litz wire winding 126, a stator yoke 127, and a stator core 128. The Litz wire winding 126, the stator yoke 127, and the stator core 128 are arranged sequentially radially inward along the propulsion unit 12. The stator yoke 127 has a slotless structure, and the stator yoke 127 and the stator core 128 are connected by a bearing 129. The Litz wire winding 126 is located radially outside the stator yoke 127 and radially inside the Halbach permanent magnet 124, forming an air gap 125 between the Halbach permanent magnet 124 and the Litz wire winding 126. Using shaped Litz wire to form the stator winding can effectively suppress the AC losses of the permanent magnet synchronous motor at high frequencies. The structural configuration of the propulsion unit 12 allows the size of the air gap 125 to be as small as possible, for example, less than 2.5mm, thereby increasing the output torque of the permanent magnet synchronous motor and thus increasing the output torque of the multiple propulsion units 12.

[0067] The stator core 128 is located radially inside the stator yoke 127. The stator yoke 127 forms a slotless structure between the Litz wire winding 126 and the stator core 128. The slotless structure can minimize torque ripple, and compared with the slotted structure, the space occupied by the stator slots in the slotted structure can be used to lay more windings, which improves the full slot ratio to a certain extent.

[0068] The specific power density of a permanent magnet synchronous motor can be expressed as:

[0069] (1)

[0070] In equation (1), K Ø It is the ratio of the electrical load on the rotor to the stator, m is the number of phases, m1 is the number of phases per stator, and K e It is the EMF factor, K i It is the current waveform factor, K p It is the electrical power waveform coefficient, η is the motor efficiency, and B g Here, A is the air gap flux density, f is the total electrical load of the motor, p is the converter frequency, and D is the number of pole pairs of the motor. g It is the air gap diameter, L e M is the effective stack length, and M is the mass of the motor.

[0071] (2)

[0072] In equation (2), and These parameters are directly proportional to the motor's speed and volume, respectively. Therefore, the specific power density of a motor is directly proportional to its air gap flux density, electrical load, and rotational speed. The motor's electrical load, or linear current density, is closely related to its heat dissipation capacity and the current density of the slots. A high electrical load increases the air gap flux density but also heats the windings, requiring a larger cooling assembly.

[0073] (3)

[0074] Equation (3) is a simplified assumption based on Equation (2), where the electromagnetic load and air gap magnetic flux density remain unchanged within a certain speed range. When the power is constant, the motor with higher speed has a smaller size; for the same size, the motor with higher speed has greater power, and the size and weight of the motor can be reduced by increasing the speed. The above formulas and theories are used to explain the key design dimensions supporting the motor. The drive shaft 11 shown in this specification directly drives the fan blade disk 22, which is essentially a low-speed, high-torque motor. Through design, the rated speed of the matching propulsion unit 12 can be designed to be in a high-speed state. According to the above formula, the high-speed design can greatly increase the weight of the motor itself, thereby increasing the power density of the motor.

[0075] Figure 7 This is a schematic diagram of a high power density propulsion assembly as shown in some embodiments.

[0076] This specification also provides a high power density propulsion assembly 100, which includes the high power density propulsion device 1 described in the above embodiments and a coordination controller 30.

[0077] The propulsion unit 12 includes a unit controller, namely Figure 7 The diagram shows the P1, P2, and P3 electrical controls. The unit controller can control the electrical output of the propulsion unit 12 (i.e., the geared motor). The unit controller can monitor the operating status data of the propulsion unit 12; that is, the P1 electrical control can monitor the operating status data of the P1 geared motor (a permanent magnet synchronous motor), the P2 electrical control can monitor the operating status data of the P2 geared motor (a permanent magnet synchronous motor), and the P3 electrical control can monitor the operating status data of the P3 geared motor (a permanent magnet synchronous motor).

[0078] The coordination controller 30 is connected to the P1, P2, and P3 electronic control signals. The coordination controller 30 controls the propulsion unit 12, namely the P1 gear motor, P2 gear motor, and P3 gear motor, based on the operating status data transmitted from these signals. The P1, P2, and P3 gear motors convert electrical energy into mechanical energy and output it through the output shaft 141, providing power for the fan 20. Essentially, the coordination controller 30 acts as a health management assembly, promptly shutting down any damaged or faulty motor among the P1, P2, and P3 gear motors to prevent further deterioration and ensure the safety of the entire high-power-density propulsion assembly.

[0079] This specification also provides an aircraft engine, including the high power density propulsion device 1 or the high power density propulsion assembly 100 of the above embodiments.

[0080] The basic concepts have been described above. It is clear that the detailed disclosure above is merely illustrative and does not constitute a limitation of this specification, especially for those skilled in the art. Furthermore, unless expressly stated in the claims, the order of elements and sequences, the use of numbers and letters, or other names in this specification are not intended to limit the order of the processes and methods described herein. Although various examples of currently considered useful embodiments of the invention have been discussed in the foregoing disclosure, it should be understood that such details are for illustrative purposes only, and the appended claims are not limited to the disclosed embodiments. Rather, the claims are intended to cover all modifications and equivalent combinations that conform to the substance and scope of the embodiments described herein.

Claims

1. A high power density propulsion device, characterized in that, The propulsion device includes: A drive shaft, on which a sun gear is mounted; Multiple propulsion units are distributed around the drive shaft. Each propulsion unit includes an external gear ring that rotates under the drive of the propulsion unit. The propulsion unit includes a slotless permanent magnet synchronous motor based on a Halbach array, and the external gear ring is sleeved on the outside of the motor. An internal gear ring surrounds the plurality of propulsion units and the drive shaft, and the external gear rings on the plurality of propulsion units simultaneously mesh with the sun gear and the internal gear ring to drive the drive shaft and the internal gear ring; The internal gear ring drives the fan blades to rotate, or the transmission shaft drives the fan blades to rotate.

2. The high power density propulsion device according to claim 1, characterized in that, The high power density propulsion device includes a planetary carrier for fixing the stator portion of the propulsion unit, and the planetary carrier is connected to the rotor portion of the propulsion unit via bearings.

3. The high power density propulsion device according to claim 1, characterized in that, The propulsion device includes 2 to 8 slotless permanent magnet synchronous motors.

4. The high power density propulsion device according to claim 1, characterized in that, The high power density propulsion device includes an outer rotor, which is sleeved on the outside of the inner gear ring. The center of the outer rotor is connected to the fan blade disk through an output shaft to drive the fan blade disk to rotate.

5. The high power density propulsion device according to claim 1, characterized in that, The high power density propulsion device includes an energy storage unit that is poweredly connected to the drive shaft. The energy storage unit is used to convert and store the kinetic energy generated by the drive shaft.

6. A high power density propulsion assembly, characterized in that, The propulsion assembly includes the high power density propulsion device according to any one of claims 1 to 5, and further includes a coordination controller; The propulsion unit includes a unit controller, which is capable of monitoring the operating status data of the propulsion unit; The coordination controller is signal-connected to the unit controller, and the coordination controller is used to control the propulsion unit according to the operating status data.

7. An aircraft engine, characterized in that, Includes the high power density propulsion device as described in any one of claims 1 to 5 or the high power density propulsion assembly as described in claim 6.

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