Attitude control-energy storage dual-purpose magnetic suspension flywheel system, unmanned aerial vehicle and control method

Abstract

The invention discloses an attitude control-energy storage dual-purpose magnetic suspension flywheel system, an unmanned aerial vehicle and a control method. The method comprises the steps that the flight stage, the attitude state and the power requirement of the unmanned aerial vehicle are detected; performing mode switching according to a detection result; in the energy management mode, the flywheel rotor kinetic energy and the electric energy are controlled to be subjected to bidirectional conversion, and high-peak discharging or efficient charging is achieved; in the attitude control mode, the active magnetic suspension bearing module is used for applying required torque to the flywheel rotor, and reaction torque is generated to the unmanned aerial vehicle body based on the gyroscopic effect for attitude adjustment; in the landing stage or the speed reduction maneuvering process of the unmanned aerial vehicle, the flywheel rotor is recharged through regenerative braking to recover energy; and under a fault or abnormal condition, the unmanned aerial vehicle executes a redundancy strategy and is switched to a standby energy or inertia emergency attitude control execution mechanism. Peak power and attitude control bandwidth can be improved simultaneously, system redundancy and weight are reduced, endurance is prolonged, reliability is improved, and the service life is prolonged.

Description

Technical Field

[0001] This invention relates to the field of unmanned aerial vehicle (UAV) and aircraft technology, and more specifically to an attitude control-energy storage dual-purpose magnetic levitation flywheel system, control method, and vertical take-off and landing UAV. Background Technology

[0002] Currently, the commonly used technical solutions for vertical takeoff and landing unmanned aerial vehicles (VTOL UAVs) in terms of energy systems, attitude control systems, and system integration, along with their respective technical shortcomings, are as follows: Energy system: Primarily relies on high-energy-density lithium polymer batteries, supplemented by supercapacitors to handle instantaneous high-power demands. There is a contradiction between high peak power demand and limited battery rate capability. Extremely high peak power demands exist during vertical takeoff and landing and hovering phases, where traditional chemical batteries struggle to balance energy density, rate capability, and lifespan, resulting in reduced flight time and limited payload.

[0003] Attitude control system: Attitude adjustment is typically achieved using aerodynamic control surfaces, differential motor thrust control, or a small anti-torque propeller. Problems include slow attitude control response and poor stability during low-speed transitions. In the low-speed / stall zone of the vertical-to-horizontal transition, low control surface efficiency and slow differential motor response make it difficult to provide sufficient rapid control torque to ensure safety.

[0004] System integration: Multiple systems, such as energy, propulsion, and attitude control, operate independently. System redundancy leads to problems such as heavy weight, high complexity, and low reliability. The lack of unified scheduling and priority management among the systems makes it impossible to cope with complex flight conditions. Summary of the Invention

[0005] The present invention provides a magnetic levitation flywheel system, a drone and control method that can simultaneously meet the requirements of high peak power output and millisecond-level attitude response, and can reduce system redundancy and weight, and can solve at least one of the above-mentioned technical problems.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A magnetic levitation flywheel system for both attitude control and energy storage includes a dual-rotor cancellation module and a dual-mode integrated controller; The dual-rotor cancellation module is used to cancel net gyro coupling and includes a flywheel rotor, an integrated motor, and an active magnetic levitation bearing module. The flywheel rotor has two sets, which are arranged along the same axis and rotate in opposite directions to store kinetic energy; The integrated motor is coaxially connected to the two sets of flywheel rotors for bidirectional conversion of kinetic energy and electrical energy. The active magnetic levitation bearing module has two sets, each including a radial magnetic bearing and an axial magnetic bearing. The two sets of active magnetic levitation bearing modules are respectively assembled with each of the flywheel rotors to provide non-contact radial and axial support for the flywheel rotors and to apply controllable radial and axial electromagnetic forces. The dual-mode integrated controller outputs attitude control signals and energy control signals to the dual-rotor cancellation module, which respectively form attitude control mode and energy management mode. In attitude control mode, differential torque is output by adjusting the speed difference between the two sets of flywheel rotors to adjust the three-degree-of-freedom attitude of the body. In energy management mode, the two sets of flywheel rotors are charged and discharged simultaneously or a single set of flywheel rotors is charged and discharged independently to meet instantaneous power demand and energy recovery.

[0007] Furthermore, the active magnetic levitation bearing module receives control commands from the dual-modal integrated controller, applies a controllable deflection torque to the flywheel rotor, and generates a reaction torque on the machine body based on the gyro effect.

[0008] Furthermore, in the active magnetic levitation bearing module, two sets of radial magnetic bearings are arranged symmetrically vertically to provide non-contact radial stability support for the flywheel rotor, and two sets of axial magnetic bearings are arranged symmetrically vertically to provide axial stability thrust for the flywheel rotor to counteract gravity and air gap disturbances.

[0009] Furthermore, the dual-mode integrated controller switches between the attitude control mode and the energy management mode, performs energy flow management according to the flight phase, and outputs corresponding attitude control torque; The energy management modes include energy storage mode and power supply mode, and the attitude control modes include pitch degree of freedom attitude adjustment mode, yaw degree of freedom attitude adjustment mode and roll degree of freedom attitude adjustment mode.

[0010] Furthermore, the dual-mode integrated controller has a task scheduling and priority switching mechanism for energy management and attitude control. During the transition flight phase, it prioritizes attitude stability and automatically switches to the energy management mode when a sudden increase in power demand is detected.

[0011] Furthermore, it also includes a vacuum-sealed housing, which provides a low-resistance environment for sealing and encapsulating the dual-rotor cancellation module. The flywheel rotor is pivotally connected to the vacuum-sealed housing via a servo frame shaft, allowing small-angle deflection to expand the output torque range and bandwidth. The vacuum-sealed housing is equipped with an electrical sealing feedthrough and a vacuum interface to reduce air friction and maintain a vacuum-sealed environment.

[0012] Furthermore, it also includes a state sensor assembly, which is distributed within the vacuum-sealed housing and is used to collect real-time data on rotor speed, attitude, bearing air gap and temperature, and to perform imbalance detection and active dynamic balancing through the health management module.

[0013] A drone has a magnetic levitation flywheel system for both attitude control and energy storage mounted inside its fuselage. The system is located near the center of gravity of the drone and is connected to the fuselage via a structural vibration isolation bracket.

[0014] Furthermore, it includes the main battery pack, lift motor, rotor, propulsion motor, avionics compartment, mission payload compartment, main flight controller, power bus, and regenerative braking recharge channel; The main flight controller and the power bus are respectively connected to the dual-mode integrated controller in the attitude control-energy storage dual-purpose magnetic levitation flywheel system. The power bus outputs power to the integrated motor in the attitude control-energy storage dual-purpose magnetic levitation flywheel system. The regenerative braking recharge channel is connected to the flywheel rotor in the attitude control-energy storage dual-purpose magnetic levitation flywheel system. This is used to realize the sharing and management of energy flow between the UAV and the attitude control-energy storage dual-purpose magnetic levitation flywheel system, and to use the attitude control-energy storage dual-purpose magnetic levitation flywheel system as the inertial emergency attitude control actuator of the UAV in an emergency.

[0015] A method for controlling a magnetic levitation flywheel that combines attitude control and energy storage, implemented using the aforementioned UAV, includes the following steps: S1. Detect the flight phase, attitude status, and power requirements of the drone; S2. Based on the test results, the attitude control-energy storage dual-purpose magnetic levitation flywheel system will be switched between attitude control mode and energy management mode; S3. In energy management mode, the integrated motor controls the bidirectional conversion of the flywheel rotor's kinetic energy and electrical energy to achieve high-peak discharge or high-efficiency charging. S4. In attitude control mode, the dual-mode integrated controller receives the three-axis attitude adjustment command from the main flight controller, applies the required torque to the flywheel rotor using the active magnetic levitation bearing module, and generates a reaction torque on the UAV body based on the gyro effect to perform attitude adjustment. S5. During the landing phase or deceleration maneuver of the UAV, the flywheel rotor is recharged through the regenerative braking recharge channel to recover energy; S6. In the event of a detected fault or anomaly, the UAV executes a redundancy strategy and switches to a backup power source or an inertial emergency attitude control actuator.

[0016] The beneficial effects of this invention are reflected in: 1. Functional Integration and Lightweight Design: Energy storage and attitude control execution are integrated into one system, reducing system weight and complexity, and freeing up payload and flight time space. Using a single system to handle peak power supply and attitude control execution reduces redundant components and cables, lowering overall weight and potential points of failure.

[0017] 2. Peak Power and Bandwidth: The flywheel can instantly output power far exceeding that of batteries of the same capacity, meeting the critical operating conditions of VTOL. The flywheel provides high-rate power output; the magnetic levitation bearing achieves millisecond-level attitude response; the dual flywheel solution further reduces gyro coupling, improving controllability and comfort.

[0018] 3. Lifespan and Efficiency: Physical energy storage offers a long cycle life and high round-trip efficiency; regeneration and recharging improve energy utilization and flight time. Gyroscopic torque provides high bandwidth and large amplitude control, significantly improving transition phase stability.

[0019] 4. Reliability: High physical energy storage cycle life, reaching hundreds of thousands of cycles, high energy return efficiency, and supports regeneration and recharging. Health management and multi-layer redundancy strategies ensure availability in complex task scenarios. Attached Figure Description

[0020] The accompanying drawings, which are provided to further illustrate this application and form part of this application, illustrate exemplary embodiments of this application and are used to explain this application, but do not constitute an undue limitation of this application.

[0021] Figure 1 This is a schematic diagram of the overall system structure according to an embodiment of the present invention.

[0022] Figure 2 This is a schematic diagram of the dual-modal control process according to an embodiment of the present invention.

[0023] Figure 3 This is a schematic diagram of the torque vector control principle according to an embodiment of the present invention.

[0024] Figure 4 This is a schematic diagram of the differential cooperative control logic flow of dual flywheels according to an embodiment of the present invention.

[0025] Figure 5 This is a schematic diagram of the overall process of the method according to an embodiment of the present invention.

[0026] Figure 6 This is a structural block diagram of a computer device according to an embodiment of the present invention.

[0027] The components in the attached diagram are labeled as follows: 101, flywheel rotor; 102, integrated motor; 103, active magnetic levitation bearing module; 103a, radial magnetic bearing; 103b, axial magnetic bearing; 104, vacuum-sealed housing; 105, dual-mode integrated controller; 106, main flight controller; 107, power bus; 108, servo frame shaft; 109, structural vibration isolation bracket; 110, status sensor assembly; 111, power management and DC / DC module; 112, thermal management module; 113, electrical sealing feedthrough; 114, vacuum interface; 115, regenerative braking recharge channel. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] It should be noted that the meaning of "and / or" throughout the text includes three parallel solutions. Taking "A and / or B" as an example, it includes solution A, solution B, or a solution that simultaneously satisfies A and B. Furthermore, "multiple" refers to two or more. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0030] See Figure 1 This invention provides a magnetic levitation flywheel system for both attitude control and energy storage, including a dual-rotor cancellation module and a dual-mode integrated controller 105; The dual-rotor cancellation module is used to cancel net gyro coupling and includes a flywheel rotor 101, an integrated motor 102, and an active magnetic levitation bearing module 103. The flywheel rotor 101 has two sets, which are arranged along the same axis and rotate in opposite directions, and are used to store kinetic energy; The integrated motor 102 is coaxially connected to the two sets of flywheel rotors 101 for bidirectional conversion of kinetic energy and electrical energy; The active magnetic levitation bearing module 103 has two sets, each including a radial magnetic bearing 103a and an axial magnetic bearing 103b. The two sets of active magnetic levitation bearing modules 103 are respectively assembled with each of the flywheel rotors 101 to provide non-contact radial and axial support for the flywheel rotors 101 and to apply controllable radial and axial electromagnetic forces. The dual-mode integrated controller 105 outputs attitude control signals and energy control signals to the dual-rotor cancellation module, which respectively form attitude control mode and energy management mode. In the attitude control mode, the differential torque is output by adjusting the speed difference between the two sets of flywheel rotors 101 to adjust the three-degree-of-freedom attitude of the body. In the energy management mode, the two sets of flywheel rotors 101 are charged and discharged simultaneously or a single set of flywheel rotors 101 is charged and discharged independently to meet instantaneous power demand and energy recovery.

[0031] See Figure 1 In this embodiment, the flywheel patent 101 is a ring structure of carbon fiber composite material with a thickened outer edge, preferably with a moment of inertia of 0.05–0.2 kg·m. 2 The operating speed range is 20,000–50,000 rpm.

[0032] See Figure 1 In this embodiment, the integrated motor 102 can be replaced by an integrated generator, selected as a permanent magnet synchronous motor / generator with a rated efficiency of ≥95%, which can provide a discharge capacity of ≥200 A@48 V during the drone hovering phase and reverse charge during the cruise phase.

[0033] In addition, the stator of the integrated motor 102 adopts a fractional slot concentrated winding, the rotor adopts a high remanence rare earth permanent magnet, and slip estimation and position-sensorless control are realized in the dual-mode integrated controller 105.

[0034] See Figure 1 In this embodiment, the active magnetic levitation bearing module 103 receives the control command from the dual-mode integrated controller 105, applies a controllable deflection torque to the flywheel rotor 101, and generates a reaction torque on the machine body based on the gyro effect.

[0035] See Figure 1 In this embodiment, in the active magnetic levitation bearing module 103, two sets of radial magnetic bearings 103a are arranged symmetrically above and below to provide non-contact radial stable support for the flywheel rotor 101, and two sets of axial magnetic bearings 103b are arranged symmetrically above and below to provide axial stable thrust for the flywheel rotor 101 to counteract gravity and air gap disturbances, with a bearing capacity ≥500 N.

[0036] See Figure 1 In this embodiment, the dual-mode integrated controller 105 switches between the attitude control mode and the energy management mode, performs energy flow management according to the flight phase, and outputs the corresponding attitude control torque; The energy management modes include energy storage mode and power supply mode, and the attitude control modes include pitch degree of freedom attitude adjustment mode, yaw degree of freedom attitude adjustment mode and roll degree of freedom attitude adjustment mode.

[0037] Furthermore, the dual-mode integrated controller 105 has a task scheduling and priority switching mechanism for energy management and attitude control. During the transition flight phase, it prioritizes attitude stability and automatically switches to the energy management mode when a sudden increase in power demand is detected.

[0038] The dual-modal integrated controller 105 implements millisecond-level closed-loop control based on FPGA / SoC, including: Attitude channel: three-axis torque distribution, rate limiting, cross-coupling compensation, and anti-integral saturation; Energy channels: bus voltage stabilization, power limiting, SOC estimation and regeneration priority management.

[0039] like Figure 2 As shown, the working mode control flow of the dual-mode integrated controller 105 is as follows: 1) Energy Management Mode During vertical takeoff and landing: flywheel discharge (speed 50,000→30,000 RPM), output current 200A@48V, lasting 30 seconds; During cruising: The solar panels charge the flywheel, increasing the speed to 50,000 RPM.

[0040] 2) Attitude control mode The main flight controller sends attitude commands (such as pitch angle +5°); The controller calculates the required torque, and the magnetic bearing applies a yaw torque to the flywheel. The gyroscopic effect generates a reaction torque to adjust the pitch of the fuselage, with a response time of <10 ms.

[0041] See Figure 1 In this embodiment, a vacuum-sealed housing 104 is also included. The vacuum-sealed housing 104 is a low-resistance environment with an internal pressure ≤0.1 Pa, used to seal and encapsulate the dual-rotor cancellation module. The flywheel rotor 101 is pivotally connected to the vacuum-sealed housing 104 via a servo frame shaft 108, allowing small-angle deflection to expand the output torque range and bandwidth. The servo frame shaft 108 can be replaced with a miniature universal joint. Furthermore, the vacuum-sealed housing 104 is provided with an electrical sealing feedthrough 113 and a vacuum interface 114 to reduce air friction and maintain a vacuum-sealed environment.

[0042] In this embodiment, a state sensor assembly 110 is also included. The state sensor assembly 110 is distributed inside the vacuum-sealed housing 104 and is used to collect real-time data on rotor speed, attitude, bearing air gap and temperature, and to perform imbalance detection and active dynamic balancing through the health management module.

[0043] This invention also provides a drone, which is equipped with the attitude control-energy storage dual-purpose magnetic levitation flywheel system. The system is located near the center of gravity of the drone and is connected to the drone body through a structural vibration isolation bracket 109.

[0044] In this embodiment, the UAV includes a main battery pack, a lift motor, a rotor, a propulsion motor, an avionics compartment, a mission payload compartment, a main flight controller 106, a power bus 107, and a regenerative braking recharge channel 115. The main flight controller 106 and the power bus 107 are respectively connected to the dual-mode integrated controller 105 in the attitude control-energy storage dual-purpose magnetic levitation flywheel system. The power bus 107 outputs power to the integrated motor 102 in the attitude control-energy storage dual-purpose magnetic levitation flywheel system. The regenerative braking and recharge channel 115 is connected to the flywheel rotor 101 in the attitude control-energy storage dual-purpose magnetic levitation flywheel system, which can recover energy by using rotor reversal regenerative braking during the landing phase, with an energy recovery rate of >40%. Thus, the UAV further realizes the sharing and management of energy flow with the attitude control-energy storage dual-purpose magnetic levitation flywheel system, and in emergency situations, the attitude control-energy storage dual-purpose magnetic levitation flywheel system can be used as the UAV's inertial emergency attitude control actuator.

[0045] The drone of this invention is arranged as follows: 1) Installation and Integration a. Layout principles: Consistent center of gravity: This system is located near the fuselage center of gravity and longitudinally close to the wing box / main beam.

[0046] Energy proximity: maintains a short path with power bus 107 and main battery pack; shares the same bus with propulsion and lift motors.

[0047] Vibration and heat isolation: The avionics and mission cabin are isolated through the heat conduction path in the structural vibration isolation bracket 109 and the thermal management module 112.

[0048] b. Internal relationships: Foreground: Mission payload compartment / sensors; Central section: This system, adjacent to the avionics compartment; Wing root: Lift motor / rotor and power controller; Tail section: Propulsion motor and power management and DC / DC module 111; Electrical: This system is connected to the power bus 107 via the electrical sealed feeder 113, and the dual-mode integrated controller 105 communicates with the main flight controller 106 via CAN / Ethernet.

[0049] Regarding the UAV and the dual-purpose magnetic levitation flywheel system for attitude control and energy storage provided by this invention, in practical applications, there are single-flywheel implementation schemes and dual-flywheel independent schemes, which are described in detail below: (I) Single Flywheel Implementation Plan 1) Structural integration: A single high-speed carbon fiber flywheel rotor 101 is coaxial with an integrated motor / generator 102. An active magnetic levitation bearing module 103 is used to achieve contactless support and controllable torque injection. It is placed in a low-pressure / vacuum housing 104 to reduce wind resistance loss and heat generation.

[0050] 2) Dual-modal cooperation: Energy management modes: such as Figure 2 As shown, the integrated motor / generator 102 and power bus 107 perform bidirectional energy conversion to provide peak power during VTOL / hovering, reverse charge during cruise, and regenerate charge via regenerative braking recharge channel 115 during landing / deceleration. Attitude control modes: such as Figure 3 As shown, the dual-modal integrated controller 105 drives the active magnetic levitation bearing module 103 to apply a deflection torque to the flywheel rotor 101 or allow micro-angle deflection, and uses the gyro effect to output a counter-torque to the body to achieve rapid control of three degrees of freedom: roll / pitch / yaw.

[0051] 3) Optimal parameters: speed range 20,000–50,000 rpm; moment of inertia 0.05–0.2 kg·m 2 Efficiency ≥ 95%; bearing bandwidth ≥ 1 kHz; internal pressure ≤ 0.1 Pa.

[0052] (ii) Independent dual-flywheel scheme 1) Core features: Two sets of flywheel rotors 101 and their respective integrated motors / generators 102 rotate in opposite directions along the same axis. The active magnetic levitation bearing module 103 is independently controlled, and net gyro coupling cancellation is achieved by utilizing opposite angular momentum.

[0053] 2) Attitude output mechanism: Differential torque control: The required triaxial equivalent torque is output by controlling the difference in torque or instantaneous speed difference between the two flywheel rotor bearings. Due to the differential action, the net gyro coupling is close to zero. Energy balance and power coordination: The energy side can charge and discharge in parallel or alternately to balance the power pulsation of the bus and reduce the heat load of a single unit.

[0054] 3) Engineering advantages: Reduces the impact of gyro coupling on the airframe structure, improves installation freedom and disturbance rejection robustness. At the same time, the dual flywheel configuration cancels out the counter-torque and counter-angular momentum brought to the UAV by the change of flywheel speed. In the absence of power output, the system maintains the conservation of angular momentum and does not output counter-torque and counter-angular momentum to the UAV body. In the presence of power output, rapid power output is achieved by finely adjusting the speed difference between the two flywheels.

[0055] See Figure 3 This invention also provides a method for controlling a magnetic levitation flywheel that serves both as an attitude control and energy storage device, implemented using the aforementioned UAV, comprising the following steps: S1. Detect the flight phase, attitude status, and power requirements of the drone; S2. Based on the test results, the attitude control-energy storage dual-purpose magnetic levitation flywheel system will be switched between attitude control mode and energy management mode; S3. In energy management mode, the integrated motor 102 is controlled to convert the kinetic energy and electrical energy of the flywheel rotor 101 in both directions to achieve high peak discharge or high-efficiency charging. S4. In attitude control mode, the dual-mode integrated controller 105 receives the three-axis attitude adjustment command from the main flight controller 106, applies the required torque to the flywheel rotor 101 using the active magnetic levitation bearing module 103, and generates a reaction torque on the UAV body based on the gyro effect to perform attitude adjustment. S5. During the landing phase or deceleration maneuver of the UAV, the flywheel rotor 101 is regenerated and recharged through the regenerative braking recharge channel 115 to recover energy. S6. In the event of a detected fault or anomaly, the UAV executes a redundancy strategy and switches to a backup power source or an inertial emergency attitude control actuator.

[0056] It should be noted that, without changing the basic functions and control logic, equivalent variations are also protected by this patent. Such equivalent variations include, but are not limited to: dual-mode collaborative and gyroscopic torque attitude control schemes implemented by using different flywheel materials, bearing topologies (electromagnetic / hybrid magnetic bearings), motor types (permanent magnet / induction / switched reluctance), bus voltage levels, sensor configurations or algorithms, etc.

[0057] To further verify the feasibility and superiority of the solution provided by this invention, a detailed explanation is given in conjunction with the following real-world experimental case: 1) Hardware Structure a. Flywheel rotor 101: Materials and Geometry: A carbon fiber composite ring rotor with thickened outer edges, preferably with an outer diameter of approximately 200 mm, a mass of approximately 3 kg, and a moment of inertia of approximately 0.12 kg·m. 2 .

[0058] Dynamic balancing: Adjustable counterweight hole positions and online dynamic balancing algorithm are set to suppress first-order / second-order unbalanced vibrations.

[0059] b. Integrated motor / generator 102: Type: Permanent magnet synchronous, fractional slot concentrated winding stator, high remanence rare earth permanent magnet rotor.

[0060] Interface: Three-phase inverter connected to bus, supports four-quadrant operation and sensorless control.

[0061] Performance: Rated efficiency ≥95%, peak current ≥200 A (48 V system).

[0062] c. Active magnetic levitation bearing module 103: Radial magnetic bearing 103a: Two sets of opposing electromagnets achieve radial non-contact support; bandwidth ≥ 1 kHz, displacement resolution ≤ 0.1 μm.

[0063] Axial magnetic bearing 103b: The upper thrust plate and coil are combined to counteract gravity and operating disturbances, and provide axial stiffness and damping.

[0064] Sensors: Eddy current / optical displacement sensors measure the air gap, and current / temperature sensors are redundantly arranged.

[0065] d. Vacuum-sealed housing 104: Environment: Internal pressure ≤0.1 Pa, to reduce wind resistance loss and heat generation.

[0066] Connections: Electrically sealed feedthrough 113 and vacuum interface 114 are used to maintain a vacuum environment and ensure safe system operation; a thermal management module 112 (heat conduction path / heating film) is installed on the outer shell to match the ambient temperature.

[0067] e. Control and power supply: Dual-modal integrated controller 105: A real-time control platform based on FPGA / SoC, communicating with the main flight controller 106 via CAN / Ethernet; managing bearing current, inverter drive, and energy flow.

[0068] Power bus 107: Connected to the motor controller, main battery pack, propulsion and lift motors, and avionics bay; power management and DC / DC module 111 provides power to low-voltage loads.

[0069] f. Structure and Installation: Miniature universal joint / servo frame axis 108: Allows small-angle deflection to improve the output torque range and control bandwidth (optional).

[0070] Structural vibration isolation bracket 109: Connected to the fuselage frame at multiple points with equal stiffness, providing high-frequency vibration isolation and low-frequency compliance.

[0071] 2) Control and Operating Modes a. Flight phase determination and scheduling: Inputs: flight phase, attitude error, power requirements, SOC, temperature and health status.

[0072] Outputs: Mode selection, triaxial torque distribution, power limiting and regeneration strategy.

[0073] b. Energy storage and power supply modes: VTOL / Hover: The flywheel releases kinetic energy from 50,000 rpm to 30,000 rpm, providing ≥200 A@48 V for approximately 30 seconds.

[0074] Cruise charging: The main battery / solar energy is used to recharge the battery to the target speed, while maintaining bus voltage regulation and current limiting.

[0075] c. Attitude control mode: Torque Channel: The main flight controller provides the three-axis torque or angular rate, the controller calculates the torque distribution, and the bearing coil outputs the equivalent deflection torque.

[0076] Bandwidth and response: Closed-loop control cycle ≤ 1 ms, attitude response delay can be as low as milliseconds.

[0077] Cross-coupling compensation: Real-time compensation for gyroscope coupling to avoid inter-axis interference.

[0078] d. Energy recovery: Landing / Deceleration: The electrical energy generated by the rotor reversal and propulsion deceleration is returned to the flywheel via the busbar to perform regenerative braking, with a preferred recovery rate of >40% (depending on the operating conditions).

[0079] Safety constraints: recharge speed limit, temperature limit and bus voltage stabilization strategy.

[0080] e. Faults and Redundancy: Health management: Monitor bearing air gap, coil temperature, speed, vibration and imbalance; if abnormal, downgrade to passive stabilization or shut down the torque channel.

[0081] Power redundancy: In case of flywheel failure, the system switches to main battery power; attitude control is taken over by the control surface / differential actuator.

[0082] 3) Example a. Example 1 (single flywheel): (1) Parameters: outer diameter 200 mm, mass 3 kg, moment of inertia 0.12 kg·m 2 Speed ​​30–50 krpm; Bus voltage 48 V; Peak voltage 8 kW.

[0083] (2) Comparison results: See Table 1 below. Compared with the battery-only solution, the peak power increased from 5 kW to 8 kW; the attitude response delay decreased from 120 ms to about 8 ms; the system weight decreased from 4.2 kg to about 2.8 kg; and the full-load hovering time increased from 8 min to about 12 min (model and mission related).

[0084] Table 1. Performance Data (Single Flywheel vs. Lithium Battery Solution)

[0085] (3) Hardware configuration: Flywheel rotor: Carbon fiber cylindrical body, outer diameter 200 mm, mass 3 kg, moment of inertia 0.12 kg·m 2 ; Magnetic bearing: electromagnetic type, bandwidth 1 kHz, displacement accuracy 0.1 μm; Controller: Xilinx Zynq FPGA, communication interface CAN 2.0.

[0086] (4) Control process: Takeoff phase: The flywheel discharges power (energy management mode), while the magnetic bearing maintains rotor stability; Transition phase: The main flight controller detects pitch oscillations, triggers attitude control modes, and applies pitch compensation torque; Cruise phase: The flywheel charges, and attitude control is taken over by aerodynamic control surfaces; Landing phase: The rotor reverses to recharge the flywheel.

[0087] (5) Industrial applications: Applicable to logistics drones, long-endurance reconnaissance drones, etc., and has passed wind tunnel testing and prototype verification.

[0088] b. Example 2 (Dual flywheel reverse cancellation): (1) Structure and configuration: It adopts a dual-flywheel coaxial counter-rotating structure, that is, two sets of flywheels of the same specification rotate in opposite directions along the same axis, and the net gyro coupling is approximately canceled out; differential torque output attitude control.

[0089] Advantages: Reduces the impact on airframe structure coupling and flight envelope, and improves installation flexibility.

[0090] The specific configuration is as follows: Flywheel rotors x2: Material: Carbon fiber composite material with thickened outer edge design; Single wheel inertia: 0.12 kg·m 2 ; Weight: Approximately 3 kg per wheel, outer diameter 200 mm; Speed ​​range: 20,000 – 50,000 rpm, with independent adjustment for both wheels.

[0091] Two integrated motors / generators: Permanent magnet synchronous motor, fractional slot concentrated winding; Rated efficiency ≥ 96%; Peak discharge capability: ≥200 A@48 V (per unit); It supports four-quadrant operation and sensorless control.

[0092] Active magnetic levitation bearing module ×2: Each flywheel is independently equipped with radial and axial magnetic bearings; Bandwidth ≥ 1 kHz, displacement resolution ≤ 0.1 μm; It can independently apply deflection torque to achieve differential control.

[0093] Vacuum-sealed housing: Shared vacuum environment, internal pressure ≤ 0.1 Pa; It is equipped with two sets of electrically sealed feeders and vacuum interfaces.

[0094] Dual-modal controller: Based on FPGA / SoC architecture, it supports dual-channel independent control; It achieves speed synchronization, differential torque calculation, and energy collaborative management.

[0095] (2) Working principle and advantages Gyroscope coupling cancellation mechanism: When the two flywheels rotate in opposite directions at the same speed, the net angular momentum is zero, there is no net gyro coupling effect, and interference with the body attitude is avoided. When attitude control is not required, the system has no impact on the drone's flight attitude, improving flight stability and natural handling.

[0096] Differential attitude control: When attitude control torque needs to be output, the controller achieves this through one of the following two methods: Differential speed control: finely adjust the speed difference between the two flywheels to generate differential angular momentum, thereby outputting control torque; Differential bearing torque control: Apply reverse deflection torque to the two flywheels and output net torque using the gyro effect.

[0097] It can achieve independent control of three degrees of freedom (roll, pitch, and yaw) with a response time of <10 ms.

[0098] (3) Energy coordination and thermal management The two flywheels can charge and discharge in parallel or alternately to balance the power fluctuations of the bus and reduce the heat load of a single unit. During the VTOL stage, both flywheels discharge simultaneously, providing a peak power multiplication (up to 16 kW@48 V). During the cruise phase, one device can be charged while the other remains in standby to maintain its attitude, thus improving system flexibility.

[0099] Table 2. Performance Data (Dual Flywheel vs. Single Flywheel Solution)

[0100] (4) Dual flywheel differential cooperative control logic, such as Figure 4 As shown: 1) Input layer: Flight phase signals: [Vertical Takeoff and Landing, Cruise, Transition, Landing] Three-axis attitude commands: [Mx, My, Mz] (from main flight controller 106) Bus power status: [V bus , I demand SOC flywhee l] Dual flywheel real-time status: [ω1, ω2, θ1, θ2, T1, T2] (speed, yaw angle, temperature) Core processing module a. Flight Mode Decision Maker Input: Flight phase signals, I demand Attitude error The control logic is as follows: If the following conditions are met: Flight phase == Vertical takeoff and landing &&I demand If the current is >150A, switch to peak power supply mode. If the following conditions are met: Flight phase: Transition &&|Attitude error|>threshold, then switch to differential attitude control mode. If the following conditions are met: Flight phase == Landing && V bus If the voltage is >50V, switch to regenerative charging mode. Default → Ready Mode (Speed ​​Maintenance) Output: Current mode b. Differential strategy solver Input: [Mx, My, Mz], [ω1, ω2] algorithm: Differential torque mode: ΔM = k·H ·Δω (preferred for yaw control) Differential yaw mode: Moutput = H × ωprecession (preferred for pitch / roll control) constraint: |ω1-ω2|<5000 rpm (mechanical stress constraint) |θ1|, |θ2|<0.5 (magnetic bearing stroke constraint) Output: [Δω_cmd, M1_cmd, M2_cmd] c. Energy Coordination Manager Input: I demand SOC flywheel1 ,2,T1, T2 Strategy: Power allocation: I1 = I_demand * (SOC1 / (SOC1 + SOC2)) (allocated according to power consumption ratio) Thermal equilibrium: If T1 > T2 + 10°C, then reduce the discharge weight of the flywheel. Fully distribute the charging current between the two wheels, or prioritize charging the wheel with the lower SOC. Output: [I_cmd1, I_cmd2] d. Health and safety monitor Input: [ω1, ω2, θ1, θ2, T1, T2, vibration signal] monitor: If the speed synchronization error meets the condition: |ω1 + ω2| > 100 rpm, then an alarm will be triggered. Bearing temperature: If T>85°C, then derating shall be performed. Vibration exceeding limits: If the vibration amplitude and frequency exceed the threshold, the online dynamic balancing algorithm is triggered. Output: Health status, degradation mode flag 2) Output layer: a. Actuator control signals To motor / generator 102 (x2): [Torque command T1, T2] / [Speed ​​command ω1, ω2] To the active magnetic levitation bearing module 103 (x2): [Deflection torque_Mx1, My1, Mz1], [Mx2, My2, Mz2] To Main Flight Controller 106: [System Status, Health Alert] To power bus 107: [Power-on / Power-off Request] b. Modal output branch Peak power supply mode: Path: Energy Coordination Manager → Motor Control → Parallel Discharge of Dual Flywheels Data: I total = I1 + I2 ≥ 400A @48V Differential attitude control modes: Path: Differential strategy solver → Magnetic bearing control → Output net torque Data: Response time < 10ms, bandwidth ≥ 100Hz Regenerative recharge mode: Path: Energy Coordination Manager → Motor Control → Dual-Flying Cycle Charging Data: Recharge efficiency > 40% c. Downgrade mode: Path: If the health and safety monitor issues a power or torque degradation command, the whole machine power mode is switched to battery power, and the flywheel switches to flywheel independent energy recovery mode.

[0101] (5) Industrial Application and Verification Applicable scenarios: Large VTOL logistics drones (payload ≥ 20 kg); long-endurance reconnaissance / mapping drones; highly mobile tactical drones.

[0102] Verified performance (based on 1:4 scale prototype testing): During the transition flight phase, the attitude stabilization time is ≤ 0.3 s; the dual flywheel coordinated discharge can last for 40 seconds at 200A; differential control accuracy: yaw torque error <5%.

[0103] Summary of advantages: Eliminating gyro coupling improves flight quality; double peak power supports larger loads or longer hovering; redundant design enhances system reliability.

[0104] c. Example 3 (Universal joint torque amplification): Structure: The rotor assembly is pivotally connected to the housing via a miniature universal joint, and small-angle deflection is driven by the servo frame shaft.

[0105] Advantages: Achieves greater equivalent attitude torque and bandwidth under the same bearing current conditions.

[0106] d. Example 4 (Thermal / Vacuum Synergy): Strategy: The housing has built-in heat-conducting pillars and an external heat sink; a heating film maintains the operating temperature of the sensor and bearing in winter; and a vacuum maintenance valve is periodically evacuated.

[0107] Effects: Reduces wind resistance loss and temperature rise, improving efficiency and lifespan.

[0108] This invention also provides a computer-readable storage medium storing a computer program, which, when executed by a processor, causes the processor to perform the steps of the attitude control-energy storage dual-purpose magnetic levitation flywheel control method described above.

[0109] See Figure 6The present invention also provides a computer device, including a memory and a processor. The memory stores a computer program. When the computer program is executed by the processor, the processor performs the steps of the attitude control-energy storage dual-purpose magnetic levitation flywheel control method described above.

[0110] This invention also provides a computer program product containing instructions that, when run on a computer, causes the computer to execute the steps of the attitude control-energy storage dual-purpose magnetic levitation flywheel control method described above.

[0111] It is understood that the system, device and storage medium provided in the embodiments of the present invention correspond to the method provided in the embodiments of the present invention, and the explanation, examples and beneficial effects of the relevant content can be referred to the corresponding parts of the above attitude control-energy storage dual-purpose magnetic levitation flywheel control method.

[0112] It should be noted that those skilled in the art will understand that all or part of the steps implemented in the embodiments of the present invention can be implemented entirely or partially by software, hardware, firmware, or any combination thereof. When implemented in hardware, it can be implemented entirely or partially by purchasing standard parts or modifications. When implemented in software, it can be implemented entirely or partially in the form of a computer program product. The computer program product includes one or more computer instructions. When the computer program instructions are loaded and executed on a computer, all or part of the processes or functions described in the embodiments of this application are generated. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wired (e.g., coaxial cable, fiber optic, digital subscriber line (DSL)) or wireless (e.g., infrared, wireless, microwave, etc.) means. The computer-readable storage medium can be any available medium that a computer can access or a data storage device such as a server or data center that integrates one or more available media. The available media may be magnetic media (e.g., floppy disks, hard disks, magnetic tapes), optical media (e.g., DVDs), or semiconductor media (e.g., solid state disks (SSDs)).

[0113] In summary, to address the shortcomings of existing technologies such as energy inconsistencies, attitude instability, and system redundancy, this invention provides an integrated magnetic levitation flywheel solution that simultaneously satisfies high peak power output and millisecond-level attitude response, while reducing system redundancy and weight. Specifically: Structural integration: carbon fiber flywheel + permanent magnet synchronous motor / generator + radial / axial magnetic levitation bearings + vacuum-sealed housing + dual-mode controller; Dual-mode coordination: The energy storage and power supply modes meet the peak power requirements of VTOL / hovering / maneuvering, while the attitude control mode achieves three-degree-of-freedom control through magnetic bearing torque injection or micro-axis deflection; Energy recovery: During the landing phase, regenerative braking is performed using rotor reversal and propulsion deceleration to recharge the fuel, thereby improving energy utilization; Layout optimization: The system is installed near the center of gravity of the machine body and coupled through vibration isolation brackets to improve the overall stability and reliability of the machine.

[0114] It should be understood that the examples and embodiments described herein are for illustrative purposes only and are not intended to limit the invention. Those skilled in the art can make various modifications or changes based on them. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the invention should be included within the protection scope of the invention.

Claims

1. A magnetic levitation flywheel system for both attitude control and energy storage, characterized in that, Includes a dual-rotor cancellation module and a dual-modal integrated controller (105); The dual-rotor cancellation module is used to cancel net gyro coupling and includes a flywheel rotor (101), an integrated motor (102), and an active magnetic levitation bearing module (103). The flywheel rotor (101) has two sets, which are arranged along the same axis and rotate in opposite directions, for storing kinetic energy; The integrated motor (102) is coaxially connected to the two sets of flywheel rotors (101) for bidirectional conversion of kinetic energy and electrical energy; The active magnetic levitation bearing module (103) has two sets, each including a radial magnetic bearing (103a) and an axial magnetic bearing (103b). The two sets of active magnetic levitation bearing modules (103) are respectively assembled with each of the flywheel rotors (101) for non-contact radial and axial support of the flywheel rotors (101) and for applying controllable radial and axial electromagnetic forces. The dual-mode integrated controller (105) outputs attitude control signals and energy control signals to the dual-rotor cancellation module, which respectively form attitude control mode and energy management mode. In the attitude control mode, the differential torque is output by adjusting the speed difference between the two sets of flywheel rotors (101) to adjust the three-degree-of-freedom attitude of the body. In the energy management mode, the two sets of flywheel rotors (101) are charged and discharged simultaneously or a single set of flywheel rotors (101) is charged and discharged independently to meet instantaneous power demand and energy recovery.

2. The attitude control-energy storage dual-purpose magnetic levitation flywheel system as described in claim 1, characterized in that, The active magnetic levitation bearing module (103) receives the control command from the dual-modal integrated controller (105), applies a controllable deflection torque to the flywheel rotor (101), and generates a reaction torque on the machine body based on the gyro effect.

3. The attitude control-energy storage dual-purpose magnetic levitation flywheel system as described in claim 1, characterized in that, In the active magnetic levitation bearing module (103), two sets of radial magnetic bearings (103a) are arranged symmetrically up and down to provide non-contact radial stable support for the flywheel rotor (101), and two sets of axial magnetic bearings (103b) are arranged symmetrically up and down to provide axial stable thrust for the flywheel rotor (101) to counteract gravity and air gap disturbance.

4. The attitude control-energy storage dual-purpose magnetic levitation flywheel system as described in claim 1, characterized in that, The dual-mode integrated controller (105) switches between the attitude control mode and the energy management mode, performs energy flow management according to the flight phase, and outputs the corresponding attitude control torque; The energy management modes include energy storage mode and power supply mode, and the attitude control modes include pitch degree of freedom attitude adjustment mode, yaw degree of freedom attitude adjustment mode and roll degree of freedom attitude adjustment mode.

5. The attitude control-energy storage dual-purpose magnetic levitation flywheel system as described in claim 1, characterized in that, The dual-mode integrated controller (105) has a task scheduling and priority switching mechanism for energy management and attitude control. During the transition flight phase, it prioritizes attitude stability and automatically switches to the energy management mode when a sudden increase in power demand is detected.

6. The attitude control-energy storage dual-purpose magnetic levitation flywheel system as described in claim 1, characterized in that, It also includes a vacuum-sealed housing (104), which is a low-resistance environment for sealing and encapsulating the dual-rotor cancellation module. The flywheel rotor (101) is pivotally connected to the vacuum-sealed housing (104) via a servo frame shaft (108), allowing small-angle deflection to expand the output torque range and bandwidth. The vacuum-sealed housing (104) is provided with an electrical sealing feedthrough (113) and a vacuum interface (114) to reduce air friction and maintain a vacuum-sealed environment.

7. The attitude control-energy storage dual-purpose magnetic levitation flywheel system as described in claim 6, characterized in that, It also includes a state sensor assembly (110), which is distributed inside the vacuum-sealed housing (104) and is used to collect real-time data on rotor speed, attitude, bearing air gap and temperature, and to perform imbalance detection and active dynamic balancing through the health management module.

8. A drone, characterized in that, The body is equipped with a magnetic levitation flywheel system for attitude control and energy storage as described in any one of claims 1-7, and the system is located near the center of gravity of the UAV body and is connected to the body through a structural vibration isolation bracket (109).

9. The UAV as described in claim 8, characterized in that, It includes the main battery pack, lift motor, rotor, propulsion motor, avionics compartment, mission payload compartment, main flight controller (106), power bus (107) and regenerative braking recharge channel (115). The main flight controller (106) and the power bus (107) are respectively connected to the dual-mode integrated controller (105) in the attitude control-energy storage dual-purpose magnetic levitation flywheel system. The power bus (107) outputs power to the integrated motor (102) in the attitude control-energy storage dual-purpose magnetic levitation flywheel system. The regenerative braking recharge channel (115) is connected to the flywheel rotor (101) in the attitude control-energy storage dual-purpose magnetic levitation flywheel system. This is used to realize the sharing and management of energy flow between the UAV and the attitude control-energy storage dual-purpose magnetic levitation flywheel system, and to use the attitude control-energy storage dual-purpose magnetic levitation flywheel system as the inertial emergency attitude control actuator of the UAV in an emergency.

10. A method for controlling a magnetic levitation flywheel that serves both attitude control and energy storage, implemented using the UAV as described in claim 9, characterized in that... Includes the following steps: S1. Detect the flight phase, attitude status, and power requirements of the drone; S2. Based on the test results, the attitude control-energy storage dual-purpose magnetic levitation flywheel system will be switched between attitude control mode and energy management mode; S3. In the energy management mode, the integrated motor (102) is controlled to convert the kinetic energy and electrical energy of the flywheel rotor (101) in both directions to achieve high peak discharge or high efficiency charging. S4. In attitude control mode, the dual-mode integrated controller (105) receives the three-axis attitude adjustment command from the main flight controller (106), applies the required torque to the flywheel rotor (101) using the active magnetic levitation bearing module (103), and generates a reaction torque on the UAV body based on the gyro effect to perform attitude adjustment. S5. During the landing phase or deceleration maneuver of the UAV, the flywheel rotor (101) is regenerated and recharged through the regenerated braking recharge channel (115) to recover energy; S6. In the event of a detected fault or anomaly, the UAV executes a redundancy strategy and switches to a backup power source or an inertial emergency attitude control actuator.

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