Integrated ducted fan device for low altitude aircraft and low altitude aircraft

Abstract

The application discloses an integrated duct device for a low-altitude aircraft and the low-altitude aircraft, and comprises a rotor disc integrated assembly, a stator shell integrated assembly and a propeller array integrated assembly; the rotor disc integrated assembly comprises a central bearing, a propeller array, an annular propeller disc outer ring and a permanent magnet; the propeller array is connected to the outer periphery of the central bearing, the inner ring side of the annular propeller disc outer ring is connected and fixed with all the propeller outer edges, and the permanent magnet is fixed to the outer ring side of the annular propeller disc outer ring; the stator shell integrated assembly comprises a duct shell main body and a coreless stator coil array integrated and fixed inside the duct shell main body; the integrated design of the rotor disc and the stator shell, the coreless coil array and the electromagnetic force simultaneously provide driving and suspension, the no-blade-tip-gap, no-tooth-slot-torque, no-iron-loss, quasi-magnetic suspension driving and zero-power-consumption passive heat dissipation are realized, and the weight, efficiency, noise and reliability are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of aircraft propulsion technology, and in particular to an integrated ducted device for low-altitude aircraft and the low-altitude aircraft itself. Background Technology

[0002] Currently, low-altitude aircraft (such as eVTOL and UAVs) have stringent requirements for power systems, including lightweight design, high power density, and low noise. Ducted fans, due to their compact structure, high aerodynamic efficiency, and relatively low noise, have become one of the ideal propulsion solutions.

[0003] Existing technologies disclose various shaftless or rim-driven ducted fans, which manufacture the stator and rotor of a traditional motor independently and then mount them separately onto the duct housing and rotor frame, using relatively complex magnetic levitation bearings or rolling bearings for rotor support and positioning. However, the aforementioned existing technologies still have some technical problems, such as: 1. Redundant structure and heavy system weight: In existing solutions, the motor and duct are assembled, with independent motor housings, stator cores, rotor frames, complex bearing systems, and other components, resulting in multiple structural layers and a large number of parts. Furthermore, the electromagnetic coupling between the rotor and stator requires an independent magnetic circuit design, further increasing the system weight and making it difficult to meet the ultra-lightweight requirements of low-altitude aircraft.

[0004] 2. Tip leakage loss leads to low efficiency and high noise: Regardless of whether it is a shaftless or rim-driven system, the blade root is fixed to the hub or runner frame. To overcome the risk of interference, a small gap (i.e., tip clearance) is still unavoidable between the blade tip and the inner wall of the duct. This gap causes high-pressure gas to leak from the pressure side of the blade to the suction side, generating tip leakage flow, resulting in volumetric loss and reduced fan efficiency. At the same time, tip leakage vortices are one of the main sources of aerodynamic noise, leading to high operating noise.

[0005] 3. Difficult heat dissipation, limiting continuous operation: Because the stator coil of the shaftless ducted fan is integrated inside the duct wall, it generates a large amount of heat during operation. Existing solutions lack an effective heat dissipation structure, making it difficult to quickly dissipate heat, resulting in excessively high coil temperature rise, which limits the continuous operation capability and service life of the device.

[0006] 4. Inherent defects in stator core: Traditional motor stators generally use silicon steel cores, which will generate cogging torque, causing torque fluctuations, affecting the stability of the fan when running at high speed, and increasing vibration and noise. At the same time, there are eddy current and hysteresis losses (i.e. iron losses) in the core, which reduce the energy conversion efficiency of the motor and generate additional heat, increasing the heat dissipation burden.

[0007] 5. The bearing system bears the main load and is subject to frictional loss and electrolytic corrosion risk: In existing solutions, both magnetic levitation bearings and rolling bearings bear the main radial and axial loads of the rotor during operation. Magnetic levitation bearings require independent controllers and windings, making the system more complex; rolling bearings suffer from mechanical frictional loss, and the current passing through the bearing can cause electrolytic corrosion (electrical discharge machining effect), which can easily lead to premature bearing failure.

[0008] Therefore, a new technical solution needs to be researched to address the above problems. Summary of the Invention

[0009] In view of this, the present invention addresses the deficiencies of the existing technology, and its main objective is to provide an integrated ducted device and a low-altitude aircraft for use in low-altitude aircraft. Through the integrated design of the rotor disk and stator housing, the coreless coil array, and the simultaneous provision of drive and levitation by electromagnetic force, it achieves zero blade tip clearance, zero cogging torque, zero iron loss, quasi-magnetic levitation drive, and zero-power passive heat dissipation, resulting in significant improvements in weight, efficiency, noise, and reliability.

[0010] To achieve the above objectives, the present invention adopts the following technical solution: An integrated ducted device for low-altitude aircraft, comprising: The rotor-disk integrated assembly includes a central bearing, a blade array, an annular disk outer ring, and a permanent magnet; the blade array is connected to the outer periphery of the central bearing, the inner ring side of the annular disk outer ring is connected to and fixed to the outer edges of all blades, and the permanent magnet is fixed to the outer ring side of the annular disk outer ring. An integrated stator housing assembly, comprising a duct housing body and a coreless stator coil array integrated and fixed inside the duct housing body; The rotor disk integrated assembly is rotatably and coaxially mounted inside the stator housing integrated assembly, such that the stator housing integrated assembly surrounds the outer periphery of the rotor disk integrated assembly, forming a working air gap between them. In operation, current is passed through the coreless stator coil array, and the resulting electromagnetic force simultaneously provides: Tangential force driving the rotor-disc integrated assembly to rotate; The radial levitation force that enables the rotor-disk integrated assembly to levitate radially; and, Axial alignment force to align the rotor blade disk integrated assembly axially.

[0011] As a preferred embodiment, the ducted outer shell or low-altitude aircraft body also has a central shaft that extends into the central bearing, which is configured to provide auxiliary support and positioning for the rotor disk integrated assembly when it is in a non-operating or power-off state.

[0012] As a preferred embodiment, the duct housing body is provided with a pneumatic cooling channel; the air inlet of the pneumatic cooling channel is located on the air inlet side of the duct device, and the air outlet of the pneumatic cooling channel is located on the air outlet side of the duct device; the pneumatic cooling channel connects the outside air with the back of the coreless stator coil array, so that the cooling airflow flows directly through the back of the coreless stator coil array to remove heat.

[0013] As a preferred embodiment, the inner ring surface of the outer ring of the annular propeller disk is seamlessly connected to the outer edge of all the blades, forming a smooth inner wall surface without blade tip gaps.

[0014] As a preferred embodiment, the central bearing, the blade array, and the outer ring of the annular propeller disk are integrally formed.

[0015] As a preferred embodiment, the coreless stator coil array is a coil array composed of multiple coreless coil units, with each group of coreless coil units serving as an independent driving structure.

[0016] As a preferred embodiment, the duct housing body includes a duct housing and a duct main structure, the interior of the duct main structure serves as a thrust output channel, the coreless stator coil array is mounted on the duct main structure, and the duct housing covers the outer periphery of the coreless stator coil array.

[0017] As a preferred embodiment, the permanent magnet is arranged with axial magnetic flux or radial magnetic flux.

[0018] As a preferred option, all blades are straight, untwisted airfoils; Alternatively, all blades can be curved, twisted airfoils; Alternatively, all blades can be three-dimensional twisted swept airfoils, with their aerodynamic shape optimized for subsonic or transonic airflow.

[0019] A low-altitude aircraft includes an aircraft body and at least one integrated ducted device for a low-altitude aircraft as described in any of the preceding claims, said integrated ducted device for a low-altitude aircraft being mounted on the aircraft body.

[0020] Compared with the prior art, the present invention has obvious advantages and beneficial effects. Specifically, as can be seen from the above technical solution: 1. Lightweight Design and Structural Reinforcement: By integrating the rotor and propeller disk into a single unit (integrated rotor-propeller-disk assembly) and the stator and housing into a single unit (integrated stator-housing assembly), redundant structures such as separate motor housings, stator cores, and rotor frames found in traditional ducted fans are eliminated. Simultaneously, the outer ring of the annular propeller disk serves as the wingtip closed loop for the blades, enhancing the structural rigidity of the entire rotor assembly. Compared to existing assembled shaftless ducted fans, this device exhibits a significant weight reduction and a substantial increase in power density.

[0021] 2. Electromagnetic force simultaneously provides drive and levitation / alignment: In operation, current is supplied to the coreless stator coil array, and the resulting electromagnetic force simultaneously provides: a tangential force to drive the rotor-disc integrated assembly to rotate, a radial levitation force to levitate it radially, and an axial alignment force to center it axially. The rotor is in a quasi-magnetic levitation state, and the central bearing does not bear the main load during operation. This eliminates the energy loss caused by bearing friction in traditional solutions and avoids the electrolytic corrosion problem caused by current passing through the bearing, thus improving system reliability.

[0022] 3. Elimination of cogging torque and iron losses: The coreless stator coil array eliminates the cogging torque caused by slotted iron cores in traditional motors, resulting in extremely stable torque output at high speeds and further reducing vibration and noise. Simultaneously, the coreless design eliminates iron losses (eddy current and hysteresis losses), improving energy conversion efficiency and giving the system faster dynamic response characteristics.

[0023] 4. Elimination of Tip Leakage Losses: The inner ring surface of the outer ring of the annular propeller disk is seamlessly connected to the outer edge of all blades, forming a smooth inner wall surface without tip clearance, thus eliminating tip clearance and preventing tip leakage flow. Compared with existing ducted fans with tip clearance, aerodynamic efficiency is significantly improved while tip leakage vortices disappear, resulting in a substantial reduction in aerodynamic noise. In particular, the propeller blades adopt three-dimensional twisted swept blades, with an aerodynamic shape optimized for subsonic or transonic airflow. This allows for better matching of the radial velocity distribution of the airflow, reducing flow losses. At the same time, the swept design staggers the acoustic phases at different radial positions of the blades, reducing the noise peaks of the blade passing frequencies and their harmonics, further improving aerodynamic efficiency and reducing noise.

[0024] 5. High-efficiency heat dissipation: The duct housing is equipped with a pneumatically driven heat dissipation channel. The air inlet is located in the low-pressure area outside the duct inlet, and the air outlet is located in the high-pressure area outside the duct outlet. The cooling airflow is driven by the natural pressure difference between the inlet and outlet during duct operation, eliminating the need for additional cooling fans or pumps and achieving zero-power heat dissipation. Furthermore, the heat dissipation channel is isolated from the working air gap, preventing dust and moisture in the cooling airflow from entering the working air gap, thus avoiding contamination and corrosion of the permanent magnet surface and degradation of coil insulation performance. The cooling airflow flows directly across the back of the coreless stator coil array, carrying away heat and effectively reducing the coil's operating temperature, delaying insulation aging, and improving the device's continuous operating capability and service life.

[0025] To more clearly illustrate the structural features and effects of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0026] Figure 1 This is a perspective view of the integrated culvert device according to Embodiment 1 of the present invention; Figure 2 This is another perspective view of the integrated culvert device according to Embodiment 1 of the present invention; Figure 3 This is a physical external structural diagram of the integrated culvert device according to Embodiment 1 of the present invention; Figure 4 This is a physical internal structure diagram of the integrated culvert device according to Embodiment 1 of the present invention; Figure 5 This is an axial cross-sectional view of the internal structure of the integrated duct device of Embodiment 1 of the present invention when axial magnetic flux arrangement is adopted; Figure 6 This is a perspective view of the rotor-disk integrated assembly according to Embodiment 1 of the present invention; Figure 7 This is an exploded view of the rotor-disc integrated assembly according to Embodiment 1 of the present invention; Figure 8 This is a cross-sectional view of the rotor-disk integrated assembly according to Embodiment 1 of the present invention; Figure 9 yes Figure 8 A magnified view of a portion of the image; Figure 10 This is an axial cross-sectional view of the internal structure of the integrated duct device of Embodiment 2 of the present invention when radial magnetic flux arrangement is adopted; Figure 11 This is a perspective view of the rotor-disc integrated assembly according to Embodiment 2 of the present invention; Figure 12 This is a front view of the rotor-disc integrated assembly according to Embodiment 2 of the present invention; Figure 13This is a perspective view of the integrated culvert device according to Embodiment 3 of the present invention; Figure 14 This is a perspective view of the integrated culvert device according to Embodiment 4 of the present invention; Figure 15 This is a perspective view of the rotor-disc integrated assembly of Embodiment 5 of the present invention (permanent magnets are not shown). Figure 16 This is another perspective view of the rotor-disc integrated assembly according to Embodiment 5 of the present invention; Figure 17 This is a physical external structural diagram of the integrated culvert device according to Embodiment 5 of the present invention; Figure 18 This is a perspective view of the rotor-disc integrated assembly of Embodiment Six of the present invention (permanent magnets are not shown). Figure 19 This is an exploded view of the rotor-disc integrated assembly of Embodiment Six of the present invention (permanent magnets are not shown). Detailed Implementation

[0027] like Figures 1 to 9 As shown, it illustrates the specific structure of Embodiment 1. An integrated ducted device for a low-altitude aircraft includes an integrated rotor disk assembly A and an integrated stator housing assembly B.

[0028] The integrated rotor-disk assembly A includes a central bearing A1, a blade array A2, an annular disk outer ring A3, and permanent magnets A5. The blade array A2 is integrally connected to the outer periphery of the central bearing A1, i.e., multiple blades extend radially outward from the central bearing A1. The inner ring of the annular disk outer ring A3 connects to and fixes the outer edges of all blades. The permanent magnets A5 are fixed to the outer ring of the annular disk outer ring A3. The permanent magnets A5 are arranged in an array, and the permanent magnets are arranged with axial magnetic flux. Figure 5The diagram illustrates the interaction between the coreless stator coil array B2 and the permanent magnet A5, as well as the working air gap. In practice, the most suitable flux arrangement can be selected based on the specific installation space, power requirements, and speed range to optimize electromagnetic performance. Because the inner ring surface of the annular propeller disk outer ring A3 is seamlessly connected to the outer edge of all blades, it forms a smooth inner wall surface without blade tip clearance, eliminating blade tip clearance and preventing tip leakage. Compared to existing ducted fans with blade tip clearance, aerodynamic efficiency is significantly improved, while tip leakage vortices disappear, and aerodynamic noise is greatly reduced. Preferably, the outer ring of the central bearing A1, the blade array A2, and the annular propeller disk outer ring A3 are integrally formed from materials such as aluminum alloy, titanium alloy, or carbon fiber composite materials (e.g., 3D printing), eliminating the connection interfaces between components (such as welding points and threaded connections), avoiding stress concentration, improving the overall structural strength and fatigue life of the rotor assembly, and facilitating high-precision dynamic balancing, reducing the number of parts and increasing strength.

[0029] like Figures 6 to 9 As shown, preferably, all blades are three-dimensional twisted swept airfoils, also known as three-dimensional twisted wide aspect ratio swept blades. Their aerodynamic shape is optimized for subsonic or transonic airflow, which can better match the radial velocity distribution of the airflow and reduce flow losses. At the same time, the swept design makes the acoustic phases of different radial positions of the blades staggered, reducing the noise peak of the blade passing frequency and its harmonics, further improving aerodynamic efficiency and reducing noise. A magnet ring assembly A4 for fixing permanent magnets A5 is provided on the outer ring side of the outer ring A3 of the annular propeller disk. This assembly includes two outer magnet rings A41 and multiple inner magnet rings A42. On the outer ring side of the outer ring A3, there are pre-set annular steps A33 at both axial ends and several axial grooves A34 connecting the two annular steps A33. On the inner ring side of the outer magnet rings A41, there are axial embedding portions A411, axial annular edges A412, and radial annular edges A413. The axial embedding portion A411 extends axially from the extended end of the axial annular edge A412. On the inner ring side of the inner magnet rings A42, there are radial embedding portions A421. Pole grooves A414 are reserved on the opposite sides of the outer magnet rings A41 and the inner magnet rings A42 for installing matching arc-shaped magnets, i.e., permanent magnets A5. Multiple arc-shaped magnets are evenly distributed circumferentially on the same magnet ring, with alternating N / S poles.

[0030] The integrated stator housing assembly B includes a ducted housing body B1 and a coreless stator coil array B2 integrated and fixed inside the ducted housing body B1. The coreless stator coil array B2 is an array composed of multiple coils wound with copper wire, without an iron core, and the magnetic lines of force at both ends of the coils participate in driving the permanent magnet A5 of the rotor. The integrated rotor disk assembly A is rotatably and coaxially mounted inside the integrated stator housing assembly B, such that the integrated stator housing assembly B is arranged around the outer periphery of the integrated rotor disk assembly A. In operation, when current is applied to the coreless stator coil array B2, the resulting electromagnetic force simultaneously provides: a tangential force driving the integrated rotor disk assembly to rotate, a radial levitation force suspending the integrated rotor disk assembly radially, and an axial centering force aligning the integrated rotor disk assembly axially.

[0031] Furthermore, the ducted housing body B1 or the low-altitude aircraft fuselage also has a central shaft B15, which extends into the central bearing A1. The central bearing A1 is configured to provide auxiliary radial and axial support and positioning only when the rotor disk integrated assembly A is in a non-operating or power-off state. Therefore, the load requirements of the central bearing A1 are significantly reduced, allowing the use of smaller, lighter, and lower-cost bearings without the need for complex lubrication and cooling systems; simultaneously, the bearing wear rate is extremely slow, extending its service life and reducing maintenance costs. The ducted housing body includes a ducted housing and a ducted main structure. The interior of the ducted main structure serves as the main channel for thrust output. The ducted main structure includes a coil mounting bracket B21 and a central shaft mounting bracket B14. The coreless stator coil array B2 is mounted on the coil mounting bracket B21 of the ducted main structure, and the central shaft B15 is disposed on the central shaft mounting bracket B14. The ducted housing covers the outer periphery of the coreless stator coil array B2. The duct main frame serves as the load-bearing structure, undertaking the dual functions of thrust output and coil installation; the duct outer shell serves as the protective layer and aerodynamic shape, with a clear division of labor that facilitates assembly. The duct outer shell comprises, in sequence, the duct head B11, the protective shell B12, and the tail cone B13.

[0032] Furthermore, the coreless stator coil array is a coil array composed of two or more sets of coreless coils, each set of coreless coils serving as an independent driving structure. For example, the coil mounting bracket B21, as the carrier device for the coils, is designed with each quarter turn as an independent structure. That is, the coil mounting bracket B21 is divided into four independent quarter-turn structures, each carrying a corresponding coil. During installation, it is inserted between axially adjacent magnet arrays, ensuring magnetic gaps during high-speed rotation. In this way, four coil units are formed. When one coil unit fails, the remaining coil units can still maintain the basic operation of the device, preventing the aircraft from suddenly crashing due to coil unit failure, thus improving the reliability and safety of the system. At the same time, different coil units can be independently controlled, achieving more precise magnetic field adjustment.

[0033] like Figures 10 to 12 As shown, this illustrates the specific structure of Embodiment 2. The integrated ducted device includes an integrated rotor-disk assembly A and an integrated stator housing assembly B. The integrated rotor-disk assembly A includes a central bearing A1, a blade array A2, an annular disk outer ring A3, and a permanent magnet A5. The integrated stator housing assembly B includes a duct housing body B1 and a coreless stator coil array B2 integrated and fixed inside the duct housing body B1. The coreless stator coil array B2 is mounted on a coil mounting bracket B21. A central shaft B15 passes through the central bearing A1 in the duct housing body B1.

[0034] Example 2 has the same main structure as Example 1, the main difference being that the permanent magnet in Example 2 is arranged with radial magnetic flux. Figure 10 The interaction between the coreless stator coil array B2 and the permanent magnet A5, as well as the working air gap, are shown.

[0035] like Figure 13As shown, it illustrates the specific structure of Embodiment 3. Embodiment 3 shares the same main structure as Embodiment 1, with the main difference being: Embodiment 3's duct housing body is equipped with a pneumatic cooling channel B16, which is isolated from the working air gap; the air inlet of the pneumatic cooling channel B16 is located on the air inlet side of the duct device, also referring to the duct head, which is a low-pressure area; the air outlet of the pneumatic cooling channel B16 is located on the air outlet side of the duct device, also referring to the duct tail, which is a high-pressure area; the pneumatic cooling channel B16 connects outside air with... The back (non-working side) of the coreless stator coil array is open, allowing cooling airflow to flow directly through the back of the coreless stator coil array to remove heat. When the duct device is working, the natural pressure difference between the inlet and outlet of the duct device drives the cooling airflow to enter from the air inlet of the pneumatic cooling channel, flow through the back of the coreless stator coil array, and exit from the air outlet of the pneumatic cooling channel. The cooling airflow direction is the same as the main airflow direction of the duct, eliminating the need for an additional fan and simplifying the structure. Preferably, independent channel holes are opened at both ends of the duct housing body, distributed circumferentially around the entire duct, without occupying additional space, resulting in a compact structure and a neat appearance.

[0036] Because of its simple structure and ingenious design, the integrated culvert device is easily deformable and expandable. In practical design, the shape of the integrated culvert device can be varied as needed, such as... Figure 14 As shown, the integrated ducted unit includes an integrated rotor disk assembly A and an integrated stator housing assembly B.

[0037] In practical design, the shape of the blades can also be flexibly varied; for example... Figures 15 to 17 As shown, the integrated rotor-disk assembly includes a central bearing A1, a blade array A2, an outer ring of the annular disk A3, and a permanent magnet A5; all blades are straight, untwisted airfoils; and mounting slots A31 are pre-set on the outer ring side of the annular disk outer ring A3. Also, as... Figure 18 and Figure 19As shown, all blades are curved twisted airfoils. It should also be noted that: the blade array A2 is connected to the outer periphery of the central bearing A1, and the inner ring of the annular disk outer ring A3 is connected to and fixes the outer edges of all blades. Specifically, multiple first grooves A11 are recessed on the outer peripheral surface of the central bearing A1. Inner end assembly block A21 and outer end assembly block A23 are integrally connected to the inner and outer edges of the blade array A2, respectively. The outer end assembly block A23 is integrally connected to all the outer edges of the blade array A2. Multiple second grooves A32 are recessed on the inner peripheral surface of the annular disk outer ring A3. The inner end assembly block A21 and outer end assembly block A23 are matched in the first grooves A11 and the second grooves A32, respectively. Seamless fixation is achieved by means of adhesive bonding, welding, etc. After assembly, the shape is consistent with the integrally formed connection, realizing the integrated effect of the central bearing A1, blade array A2, and annular disk outer ring A3. This is equivalent to the outer end assembly block A23 being embedded in the second groove A32, filling the second groove A32 on the outer ring A3 of the annular propeller disk, forming a complete outer ring A3 of the annular propeller disk. The inner end assembly block A21 is embedded in the first groove A11, filling the first groove A11 on the central bearing A1, forming a complete central bearing A1. Similarly, for propeller blades of other shapes, this or a similar integrated assembly method can be used. A slight design variation is also possible, where only one end of the propeller blade is integrally connected to the assembly block, while the other end is integrally connected to the central bearing A1 or the outer ring A3 of the annular propeller disk. In this way, only one end has an assembly relationship. Furthermore, the outer ring A3 of the annular propeller disk can be a single, integrally formed ring, or it can be divided into two or more parts and then assembled into a single unit.

[0038] Furthermore, a low-altitude aircraft is provided, which may be an electric vertical takeoff and landing aircraft, an unmanned aerial vehicle, or an urban air traffic vehicle, etc., including an aircraft body and at least one integrated ducted device for low-altitude aircraft as described in any of the preceding claims, wherein the integrated ducted device for low-altitude aircraft is mounted on the aircraft body. If there are multiple ducted devices, they can be connected in parallel or series to form a power module, and each integrated ducted device can be independently controlled to achieve thrust distribution in different flight modes such as vertical takeoff and landing, hovering, and forward flight.

[0039] Next, a brief introduction to its working principle: When the aircraft requires thrust, the control system supplies a specific three-phase alternating current to the coreless stator coil array B2. The magnetic field generated by the coreless stator coil array B2 interacts with the permanent magnet A5. According to the principles of electromagnetism, this interaction force simultaneously generates three components: 1. Tangential force: driving the rotor-disk integrated assembly to rotate around its axis; 2. Radial levitation force: pulling the rotor towards the center, maintaining radial alignment within the working air gap; 3. Axial alignment force: holding the rotor in a predetermined axial position. Under the combined action of electromagnetic forces, the rotor-disk integrated assembly A is in a quasi-magnetic levitation state, and the central bearing A1 does not bear the main load. The rotor-disk integrated assembly A rotates at high speed, and the blade array A2 performs work, generating a low-noise, high-velocity airflow, thereby outputting thrust. Typically, the central bearing A1 and the outer ring A3 of the annular disk can also generate some thrust.

[0040] Furthermore, regarding the verification of beneficial effects, simulation tests were conducted: (e.g.) Figure 3 The demonstrator shown has a propeller disk diameter of 223 mm. With all drive units installed, the speed exceeds 4000 rpm, and the propeller efficiency exceeds 5 g / W. Compared to existing shaftless ducted fans with blade tip clearance, its aerodynamic efficiency is effectively improved. Compared to traditional iron-core motors, torque fluctuation is significantly reduced. The overall structural weight is significantly lighter than the traditional motor + duct design. Moreover, the operating noise is significantly lower than existing solutions.

[0041] In summary, from the perspective of the overall technical solution, this invention achieves zero blade tip clearance, zero cogging torque, zero iron loss, quasi-magnetic levitation drive, and zero-power passive heat dissipation by integrating the rotor and propeller disk, integrating the stator and housing, and employing an electromagnetic coupling structure of a coreless stator coil array and permanent magnets. Specifically, the absence of blade tip clearance completely eliminates blade tip leakage flow, improving aerodynamic efficiency and reducing noise; the coreless coils eliminate cogging torque and iron loss, reducing torque fluctuation and ensuring extremely smooth operation; the electromagnetic force simultaneously provides tangential drive, radial levitation, and axial alignment, ensuring that the bearings do not bear the main load during operation, eliminating mechanical friction loss and the risk of electrolytic corrosion, and significantly extending bearing life; the integrated structure eliminates redundant components such as independent motor housings, stator cores, and impeller frames, reducing the overall weight; and the independent heat dissipation channel driven by the natural pressure difference at the duct inlet and outlet achieves zero-power efficient cooling of the coils. These technical features work together, and the combined effects of the above-mentioned technologies enable the present invention to surpass existing shaftless ducted fans in key indicators such as weight, efficiency, noise, power density, and reliability. It is especially suitable for low-altitude aircraft with stringent requirements for lightweight, high thrust-to-weight ratio, and low noise.

[0042] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. An integrated ducted device for low-altitude aircraft, characterized in that, include: The rotor-disk integrated assembly includes a central bearing, a blade array, an annular disk outer ring, and a permanent magnet; the blade array is connected to the outer periphery of the central bearing, the inner ring side of the annular disk outer ring is connected to and fixed to the outer edges of all blades, and the permanent magnet is fixed to the outer ring side of the annular disk outer ring. An integrated stator housing assembly, comprising a duct housing body and a coreless stator coil array integrated and fixed inside the duct housing body; The rotor disk integrated assembly is rotatably and coaxially mounted inside the stator housing integrated assembly, such that the stator housing integrated assembly surrounds the outer periphery of the rotor disk integrated assembly, forming a working air gap between them. In operation, current is passed through the coreless stator coil array, and the resulting electromagnetic force simultaneously provides: Tangential force driving the rotor-disc integrated assembly to rotate; The radial levitation force that enables the rotor-disk integrated assembly to levitate radially; and, Axial alignment force to align the rotor blade disk integrated assembly axially.

2. The integrated ducted device for low-altitude aircraft according to claim 1, characterized in that: The ducted outer shell or low-altitude aircraft body also has a central shaft that extends into the central bearing, which is configured to provide auxiliary support and positioning for the rotor disk integrated assembly when it is in a non-working or power-off state.

3. The integrated ducted device for low-altitude aircraft according to claim 1, characterized in that: The duct housing is provided with a pneumatic cooling channel; the air inlet of the pneumatic cooling channel is located on the air inlet side of the duct device, and the air outlet of the pneumatic cooling channel is located on the air outlet side of the duct device; the pneumatic cooling channel connects the outside air with the back of the coreless stator coil array, so that the cooling airflow flows directly through the back of the coreless stator coil array to remove heat.

4. An integrated ducted device for low-altitude aircraft according to claim 1, characterized in that: The inner ring surface of the outer ring of the annular propeller disk is seamlessly connected to the outer edge of all the blades, forming a smooth inner wall surface without blade tip gaps.

5. An integrated ducted device for low-altitude aircraft according to claim 1, characterized in that: The central bearing, the blade array, and the outer ring of the annular propeller disk are integrally formed.

6. An integrated ducted device for low-altitude aircraft according to claim 1, characterized in that: The coreless stator coil array is a coil array composed of multiple coreless coil units, with each group of coreless coil units serving as an independent driving structure.

7. An integrated ducted device for low-altitude aircraft according to claim 1 or 4, characterized in that: The duct housing body includes a duct housing and a duct main structure. The interior of the duct main structure serves as a thrust output channel. The coreless stator coil array is mounted on the duct main structure. The duct housing covers the outer periphery of the coreless stator coil array.

8. An integrated ducted device for low-altitude aircraft according to claim 1, characterized in that: The permanent magnet is arranged with axial magnetic flux or radial magnetic flux.

9. An integrated ducted device for low-altitude aircraft according to claim 1, characterized in that: All blades are straight, untwisted airfoils; Alternatively, all blades can be curved, twisted airfoils; Alternatively, all blades can be three-dimensional twisted swept airfoils, with their aerodynamic shape optimized for subsonic or transonic airflow.

10. A low-altitude aircraft, comprising an aircraft body, characterized in that, It also includes at least one integrated ducted device for a low-altitude aircraft as described in any one of claims 1 to 9, wherein the integrated ducted device for a low-altitude aircraft is mounted on the aircraft body.

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