Electric aircraft propulsion system
By designing modular power electronics modules and plug-and-play connectors, the problems of large footprint and heat loss in conventional power electronics architectures in aircraft have been solved, resulting in an electric propulsion system with a smaller footprint, lighter weight, and higher availability.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- SAFRAN ELECTRICAL & POWER
- Filing Date
- 2024-11-19
- Publication Date
- 2026-06-19
AI Technical Summary
Conventional power electronic architectures occupy a large area and are heavy in aircraft, making them difficult to integrate into the nacelle area. They also suffer from heat loss and space-consuming power wiring harnesses.
Interchangeable power electronics modules are used, which are connected to the motor and cooling equipment via plug-and-play connectors to form a modular electric propulsion system. This reduces the use of power wiring harnesses and allows the motor and power electronics to be cooled by a single cooling device.
This enables easy disassembly and replacement of power electronic modules, reduces the system's footprint and weight, improves system availability and maintenance convenience, and reduces heat loss.
Smart Images
Figure CN122249979A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the general field of electric propulsion systems for aircraft, and more specifically, to the mechatronics integration of power electronic devices and electric propulsion systems.
[0002] Conventional (CTOL), short takeoff and landing (STOL), and vertical takeoff and landing (VTOL) aircraft are powered by electric or hybrid electric / thermal propulsion provided by one or more motors. The conventional motor control architecture includes a DC voltage source connected via power harnesses to power electronics and control equipment, which in turn are connected to the motors via power harnesses. The motors themselves are connected to the propellers via rotors, gearboxes, or other transmission devices.
[0003] In this conventional architecture, the components are integrated separately according to their functions, but they have a fairly high total mass and footprint, especially for high power ratings (greater than 200 kW).
[0004] In addition, to reduce heat loss, the power harnesses used have a large diameter due to the large current flowing through them.
[0005] In addition, power electronic components are typically rectangular in shape and are not easily integrated into the nacelle area.
[0006] Therefore, conventional power electronic architectures are not suitable for direct integration on rotating machinery and in nacelle areas; they require multiple sets of electrical harnesses, occupy space and generate heat loss; they have a large mass and footprint, making them difficult to access and maintain, especially when electrical paths need to be separated and / or replicated to ensure availability and operational safety to meet certification requirements.
[0007] Therefore, there is a need for a new power electronic architecture for motors that can be better integrated into the nacelle area with a smaller footprint and reduced mass, while supporting high power levels. Summary of the Invention
[0008] This invention relates to an electric propulsion system for an aircraft, comprising: An electric motor configured to operate as a motor or generator, and including a rotor; DC voltage source; Power electronic equipment, which is connected to a DC voltage source and a motor; and Cooling equipment, which uses heat transfer fluids to cool motors and power electronic devices. The power electronic device is characterized by comprising at least two interchangeable power electronic modules configured to each form an electrical path from a DC voltage source to a motor. Each module includes at least one first plug-and-play connector configured to connect to the motor and transmit electrical signals, a second plug-and-play connector configured to connect to the motor and transmit power, and a third plug-and-play connector configured to connect a cooling device to the motor. The electric propulsion system includes a receiving structure attached to the motor, on which the power electronic modules are placed, and the receiving structure defines an empty volume around the axis of the motor's rotor.
[0009] Therefore, the power electronics module can be removed and replaced online on the aircraft.
[0010] The presence of several interchangeable power electronic modules enables modular electric propulsion systems where modules are easily replaceable and interchangeable, and the redundancy of the electrical paths formed by the modules improves the availability of the powertrain. Module maintenance is also easier because the modules can be easily disassembled and / or interchanged.
[0011] With their smaller size compared to power electronic devices, these modules are better able to handle environmental constraints, such as vibration due to fewer fasteners, or humidity due to less condensation in their smaller volume.
[0012] Furthermore, plug-and-play connectors allow power electronics modules to be installed "blindly" into cooling equipment and motors in a single operation by directly connecting the modules to the cooling equipment and motors. They also eliminate the need for dedicated cables between the power electronics modules and the motors. This thus removes the need for power harnesses between the two.
[0013] In particular, the first plug-and-play connector is capable of transmitting electrical signals with low voltage and current levels between the motor and the power electronics module, such as signals from sensors present in the aircraft, for example, located in the motor.
[0014] The second plug-and-play connector can transmit power between the motor and the power electronics module, i.e., it can transmit the power supply.
[0015] The third plug-and-play connector is a hydraulic connector because it allows heat transfer fluid from the cooling system to pass between the power electronics module and the motor. It connects the motor to the cooling system.
[0016] Depending on a specific characteristic of the system, at least two power electronic modules can be identical.
[0017] Because of these modules, it is also easier to adapt to the footprint allocated to power electronic devices, and these modules will be smaller than a single conventional power electronic block.
[0018] The plug-and-play connectors on the modules eliminate the need for power harnesses between the power electronics and the motors. This reduces the footprint and weight of the propulsion system.
[0019] Finally, the close proximity of the modules and motors allows for the simultaneous cooling of both the motors and power electronics using a single cooling device, which reduces the overall mass and volume of the electric propulsion system.
[0020] Furthermore, the receiving structure can be a separate structure consisting of one or more components, or it can be integrated into the motor. This facilitates the installation of power electronics modules onto the motor and allows them to bear part of the load.
[0021] For example, it is a structure made of stainless steel sheet, formed by two parts assembled together and fastened to the motor.
[0022] According to a particular feature of the invention, at least one of the plug-and-play connectors is placed on the motor-facing side of the power electronics module.
[0023] In other words, at least one of the motor-facing faces of the power electronics module will be supported on the rear face of the motor by a plug-and-play connector similar to a blind-mating connector.
[0024] This means that the connection between the motor and the power electronics module can be completely blind.
[0025] According to another specific feature of the invention, at least one of the plug-and-play connectors is placed on the side of the power electronics module.
[0026] In other words, at least one of the plug-and-play connectors is placed on the accessible face of the power electronics module for installation.
[0027] According to another specific feature of the invention, the receiving structure includes a positioning guide to ensure automatic alignment between the plug-and-play connector of the power electronics module and the motor.
[0028] These positioning guides can help install the module onto the motor by aligning the module and its plug-and-play connector with the motor (as well as the motor's own connectors for power, electrical signals, and heat transfer fluids for cooling equipment).
[0029] According to another specific feature of the invention, the electric propulsion system includes fastening devices placed on the power electronics module, which are configured for assembling the power electronics module with a receiving structure and / or for assembling the power electronics module with a motor and / or for assembling the power electronics module with each other.
[0030] These fastening devices hold the module in place on the motor and reinforce the entire electric propulsion system.
[0031] According to a particular feature of the invention, the power electronic module has a power between 100 kW and 300 kW, for example, 200 kW.
[0032] Another specific feature of the invention is that the motor is a permanent magnet motor.
[0033] According to another specific feature of the invention, the electric propulsion system includes a propeller pitch actuator placed along the rotor axis in an empty volume.
[0034] In this case, the actuator can be pressed against the structure of the receiving power electronic device to secure it.
[0035] The actuator can also be controlled by power electronic devices or by another external control component.
[0036] According to one embodiment of the present invention, the system is a vertical takeoff and landing (VTOL) aircraft propulsion system.
[0037] According to another embodiment of the present invention, the system is a short takeoff and landing (STOL) aircraft propulsion system.
[0038] According to another embodiment of the present invention, the system is a conventional aircraft (CTOL) propulsion system.
[0039] Another object of the present invention is an aircraft having electric or hybrid electric / thermal propulsion with a propulsion system according to the present invention. Attached Figure Description
[0040] Other features and advantages of the invention will become apparent from the following description with reference to the accompanying drawings, which illustrate exemplary embodiments in a non-limiting manner.
[0041] [ Figure 1 ] Figure 1 A partial schematic diagram of an electric propulsion system according to an embodiment of the present invention is shown.
[0042] [ Figure 2 ] Figure 2 A partial schematic diagram of a plug-and-play connector present on the power electronics module of an electric propulsion system according to an embodiment of the present invention is shown.
[0043] [ Figure 3 ] Figure 3 A partial schematic diagram of a positioning guide for the power electronics module of an electric propulsion system according to an embodiment of the present invention is shown.
[0044] [ Figure 4 ] Figure 4A partial schematic diagram of a plug-and-play connector present on the power electronics module of an electric propulsion system according to another embodiment of the present invention is shown.
[0045] [ Figure 5 ] Figure 5 A partial schematic diagram of the fastening devices of the power electronics module of an electric propulsion system according to an embodiment of the present invention is shown, relating to each other and to the motor. Detailed Implementation
[0046] In the instruction manual, the term "power electronics" also refers to "power and control electronics".
[0047] Figure 1 This is a partial schematic diagram of an electric propulsion system 100 according to an embodiment of the present invention.
[0048] The electric propulsion system 100 includes a motor 110 configured to operate as a motor or generator; power electronics 120; a DC voltage source connected to the power electronics 120; and cooling devices 172 and 173 for cooling the power electronics 120 and the motor 110 using heat transfer fluids.
[0049] The motor 110 includes a rotor, which may be hollow or not, and the power electronics 120 includes four power electronic modules 121, 122, 123, and 124. Modules 121, 122, 123, and 124 are interchangeable. In other words, each electronic module includes an interface that can be placed on each outer surface of the receiving structure 130. In other words, the power electronic modules may include interfaces compatible with the receiving structure in terms of electrical connectivity and mechanical characteristics (non-exhaustive examples include connectors, attachment areas, allocated volumes, etc.). They have the functionality and performance necessary to respond to demands and desired performance.
[0050] Depending on a specific characteristic of the system, at least two power electronic modules can be identical.
[0051] Each of these modules supplies power to one electrical path from the DC voltage source to the motor 110, thus forming four independent electrical paths. These modules 121, 122, 123, and 124 provide isolation and redundancy for the electrical paths. This increases the overall availability of the electric propulsion system 100. The propulsion system 100 may also include an inverter for each electrical path (therefore four inverters in this example), which is connected to the power electronics module, and each inverter can supply one-quarter of the total power to the motor 110.
[0052] The electric propulsion system 100 includes a receiving structure 130 attached to a motor 110, on the outer surface of which four power electronic modules 121, 122, 123, and 124 are disposed. The receiving structure 130 thereby defines an empty volume 135 around the axis of the rotor of the motor 110. This empty volume can, for example, receive a system for actuating the pitch of the blades of a propeller driven by the motor 110 or a system for de-icing the propeller blades, which will be aligned with the axis of the rotor of the motor 110. Therefore, the propeller control mechanism can be moved to the center of the propulsion system 100, resulting in a compact system.
[0053] Therefore, the power electronics 120 is placed on the rear of the motor 110, which eliminates the need for power harnesses and electromagnetic filters between the motor 110 and the power electronics modules 121, 122, 123, 124.
[0054] Because the power electronics modules 121, 122, 123, and 124 are placed as close as possible to the motor 110, single cooling devices 172 and 173 are used to cool both the motor 110 and the power electronics modules 121, 122, 123, and 124. Therefore, a heat transfer fluid, such as oil, a glycol solution, or another heat transfer fluid, first cools the modules 121, 122, 123, and 124, and then the motor 110. Loops 172 and 173 represent examples of heat transfer fluid flow through modules 122 and 123.
[0055] Using a single common cooling device reduces the total mass of the electric propulsion system 100.
[0056] Each module 121, 122, 123, 124 includes: a first plug-and-play connector configured to connect to the motor 110 and transmit electrical signals. Figure 2 The figure references 252 and 292 are visible in the figure. Figure 3 The attached figure reference 392, and Figure 4 (See reference numeral 492 in the attached figure); a second plug-and-play connector configured to connect to the motor 110 and transmit power ( Figure 1 Connector 154 for module 124 and connector 151 for module 121 Figure 2 The figure references 282 and 251 are visible in the figure. Figure 3 The figure reference numerals 352 and 352 are visible in the figure. Figure 4 (See reference numeral 452 in the attached figure); and a third plug-and-play connector configured to connect the cooling system to the motor ( Figure 2 The attached figure 271 is visible in the figure. Figure 3 The attached figure 3722 is visible in the figure. Figure 4 (See attached figure 472).
[0057] Reference Figure 2 , Figure 3 and Figure 4 These plug-and-play connectors will be described in more detail.
[0058] The electric propulsion system 100 also includes positioning guides 142 and 143 to ensure automatic alignment between the plug-and-play connectors of modules 121, 122, 123, and 124 and the motor 110. Figure 1 Only the guides 142 and 143 of modules 122 and 123 are shown.
[0059] Reference Figure 3 These positioning guides 142 and 143 are described in more detail.
[0060] Fastening devices 161 and 164 are also placed on modules 121, 122, 123, and 124 for assembling the modules with the motor 110, and for referencing... Figure 5 To describe in more detail.
[0061] Figure 2 As shown Figure 1 Partial schematic diagram of the two power electronic modules 221 and 222 and their plug-and-play connectors described herein.
[0062] exist Figure 2 In (a), the power electronics module 222 includes on its face 222a: a plug-and-play connector 282 configured to transmit power to a motor; a plug-and-play connector 252 configured to transmit electrical signals to the motor; and a plug-and-play connector 272 configured to connect a cooling device to the motor. More specifically, connector 272 is used to circulate the power electronics module 222 toward the motor after the heat transfer fluid has cooled the module.
[0063] The face 222a of module 222 faces the motor. Therefore, the plug-and-play connectors 282, 252 and 272 are positioned as close to the motor as possible, and a completely blind connection is formed when module 222 is assembled with the aforementioned receiving structure attached to the motor.
[0064] exist Figure 2 In (b), the power electronics module 221 includes, on its face 221a facing the motor 210: a plug-and-play connector 251 configured to transmit power to the motor 210; and a plug-and-play connector 271 configured to connect a cooling device to the motor 210. Therefore, heat transfer fluid is directly transferred from module 221 to the motor 210. Figure 2 As in (a), when module 221 is assembled with motor 210 via receiving structure, the connection is thus formed as a blind connection.
[0065] Module 221 also includes a fastening device 261 on one side, facing the motor 210, allowing module 221 to be assembled with the motor 210. This strengthens the assembly of the module with the motor.
[0066] Figure 2 (c) shows an example of a plug-and-play connector 292 present on the face 222a of the power electronics module 222 facing the motor 210. The connector 292 transmits electrical signals to the machine 210.
[0067] Figure 3 It shows that it exists in the reference Figure 1 and Figure 2 A partial schematic diagram of the positioning guides 342 and 3421 on the power electronics module 322.
[0068] like Figure 2 As shown, the power electronics module 322 may include plug-and-play connectors 352, 392 and 372 on its motor-facing face 322a. The plug-and-play connectors 352, 392 and 372 are configured to transmit electrical signals (connector 392) and power (reference numeral 352) to the motor, and to connect a cooling device to the motor (connector 3722).
[0069] like Figure 3 As shown in (b), the heat transfer fluid from the cooling device flows around module 322, enters via connector 3722 connected to the cooling device, then enters flow loop 3721, and exits via connector 372 to flow to the motor.
[0070] Module 322 includes a first positioning guide 342 for positioning module 322 on receiving structure 330. Figure 3 (a) More specifically, the first positioning guide 342 is used to guide the module 322 on the receiving structure and preposition the respective plug-and-play connectors 352, 372 of the module 322 at the corresponding input portion of the motor. The first positioning guide 342 may, for example, be formed by a shape present on the module 322 that will be inserted into and slide in a slot present on the receiving structure 330.
[0071] Module 322 also includes a second positioning guide 343 for positioning module 322 on the motor. Figure 3 (b) The second positioning guide 343 may be, for example, a positioning pin that inserts into a slot or hole present on the motor. It enables the module 322 to be precisely aligned with the motor to ensure that the plug-and-play connectors 352, 372 enter the corresponding input section of the motor.
[0072] Figure 4A partial schematic diagram of the plug-and-play connectors 452, 472, 492 and the positioning guide 443 of the power electronics module 422 is shown.
[0073] As mentioned above ( Figure 3 The power electronic module 422 includes, on its motor-facing side 422a: a positioning guide, more specifically a positioning pin 443, for precisely aligning the module 422 with the motor; and a plug-and-play connector 472 for connecting cooling equipment to the motor and a plug-and-play connector 492 for transmitting electrical signals to the motor.
[0074] In this second example, the power electronics module 422 includes a plug-and-play connector 452 on its side 422b (a face parallel to the axis of the motor's rotor and not facing the empty volume defined by the structure housing the power electronics module). The plug-and-play connector 452 is configured to transfer power from the module 422 to the motor.
[0075] The plug-and-play connectors on face 422a or face 422b of module 422 thus eliminate power harnesses and cables between the power electronics and the motor. This reduces the overall mass and volume of the electric propulsion system. Furthermore, by eliminating power harnesses, filters specifically designed for electromagnetic interference can also be reduced or even eliminated.
[0076] Figure 5 This shows the connection between the two power electronics modules 521 and 522 ( Figure 5 (a) and between power electronic modules 521, 522 and motor 510 ( Figure 5 (b) is a partial schematic diagram of the fastening device.
[0077] As indicated in the foregoing figures and Figure 5 As shown in (a) and 5(b), the two power electronic modules 521 and 522 may include means 581, 582 for fastening to the motor 510. More specifically, these means 581, 582 enable the motor-facing face 522a to be fastened to the motor so that the module remains in place and the plug-and-play connector is properly positioned in the connector present on the motor.
[0078] Fastening devices 581 and 582 can also be used to provide electrical grounding of the motor and modules 521 and 522 via the contact portion of the conductive surface when the surfaces of the motor and modules 521 and 522 are conductive.
[0079] Module 522 includes a fastening device 580 for fastening it to another module.
[0080] The module may also include fastening devices to enable it to be assembled with the receiving structure.
[0081] Various fastening devices 580, 581, and 582 (fastening) to the receiving structure, (fastening) to the motor and / or module can improve the overall rigidity of the electric propulsion system.
[0082] Plug-and-play connectors designed for cooling equipment, allowing heat transfer fluid to flow between the module and the motor, can be rigid to help align the module with the motor.
[0083] Depending on a specific characteristic of the system, a plug-and-play connector can be a plug-in connector.
[0084] Due to another special feature of the system, the connector can be rigid and pluggable, allowing for "blind" installation.
[0085] The motor is, for example, a permanent magnet synchronous motor.
[0086] Power electronic devices can have power ranging from 200 kW to 800 kW, with each power electronic module having power ranging from 100 kW to 300 kW.
[0087] The electric propulsion system according to the invention can be, for example, a propulsion system for conventional aircraft (CTOL), a propulsion system for vertical takeoff and landing aircraft (VTOL), or a propulsion system for short takeoff and landing aircraft (STOL).
[0088] The present invention also relates to an aircraft comprising an electric propulsion system according to the present invention.
Claims
1. An electric propulsion system (100) for an aircraft, comprising: Electric motors (110, 210, 510), said electric motors (110, 210, 510) configured to operate as motors or generators, and including rotors, DC voltage source; Power electronic equipment (120), the power electronic equipment (120) being connected to the DC voltage source and the motor; and Cooling devices (172, 173, 3721, 3722) are used to cool the motor and the power electronic equipment using heat transfer fluids. The power electronic device is characterized in that it comprises at least two interchangeable power electronic modules (121, 122, 123, 124, 221, 222, 322, 422, 521, 522), the at least two interchangeable power electronic modules being configured to each form an electrical path from the DC voltage source to the motor, each module comprising at least one first plug-and-play connector (252, 292, 392, 492) configured to connect to the motor and transmit electrical signals, a second plug-and-play connector (151, 154, 251, 282, 352, 452) configured to connect to the motor and transmit power, and a third plug-and-play connector (271, 272, 372, 472) configured to connect the cooling device to the motor, and the electric propulsion system comprising a receiving structure (130, 330) attached to the motor, the power electronic modules being placed on the receiving structure, and the receiving structure defining an empty volume (135) around the axis of the rotor of the motor.
2. The electric propulsion system according to claim 1, characterized in that, At least one of the plug-and-play connectors (151, 154, 251, 252, 282, 292, 272, 271, 352, 372, 392, 472, 492) is placed on the motor-facing side (221a, 222a, 322a, 422a) of the power electronic module (221, 222, 322, 422).
3. The electric propulsion system according to any one of claims 1 or 2, characterized in that, At least one of the plug-and-play connectors (452) is located on the side (422b) of the power electronics module (422).
4. The electric propulsion system according to any one of claims 1 to 3, characterized in that, The receiving structure (130, 330) includes positioning guides (142, 143, 342, 343, 443) that provide automatic mutual alignment between the plug-and-play connector of the power electronics module and the motor.
5. The electric propulsion system according to any one of claims 1 to 4, characterized in that, Includes fastening devices (161, 164, 261, 580, 581, 582) placed on the power electronic module, the fastening devices (161, 164, 261, 580, 581, 582) being configured to assemble the power electronic module onto the receiving structure and / or assemble the power electronic module with the motor and / or assemble the power electronic modules with each other.
6. The electric propulsion system according to any one of claims 1 to 5, characterized in that, Each power electronics module has a power output between 100 kW and 300 kW.
7. The electric propulsion system according to any one of claims 1 to 6, characterized in that, The motor is a permanent magnet synchronous motor.
8. The electric propulsion system according to any one of claims 1 to 7, characterized in that, Includes a propeller pitch actuator located in the empty volume along the rotor axis.
9. The electric propulsion system according to any one of claims 1 to 8, characterized in that, The system is a propulsion system for vertical takeoff and landing (VTOL) aircraft, a propulsion system for short takeoff and landing (STOVL) aircraft, or a propulsion system for conventional aircraft.
10. An aircraft having electric propulsion or a hybrid thermal / electric propulsion system, comprising an electric propulsion system according to any one of claims 1 to 9.