Aircraft Ground Power Unit With Replaceable Power Modules
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Solution Overview
Problem
Existing ground power units require time-consuming and costly maintenance due to the structural integration of power electronic components, making replacement difficult and resource-intensive.
Innovation Solution
The design of structurally independent rectifier and inverter modules that can be easily replaced, with a cable system and ergonomic positioning for quick and economic maintenance, along with plug connections and quick-release connectors for safe and tool-free operation, and parallel module configurations for redundancy and load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If all power electronic components are installed in a control cabinet as a fully integrated structure, then the system structure is compact and unified, but the components can be replaced only in a time-consuming manner and using special tools, and replacement involves great expenditures
Solution Approach 1:
The control cabinet is divided into individual module units (rectifier modules, inverter modules, control modules) that can be independently replaced. Each module is a self-contained unit with its own housing and connections, allowing selective replacement without disassembling the entire control cabinet structure.
Solution Approach 2:
Power electronic components are extracted from the integrated control cabinet structure and placed into separate, removable module housings. This extraction allows modules to be independently handled, removed, and replaced without affecting the remaining system components.
2Reliability
If individual modules are replaced only by replacing the entire control cabinet or using special tools, then system integrity is maintained, but maintenance time and cost increase significantly
Solution Approach 1:
The system is segmented into standardized modules that maintain electrical and functional integrity through proper connection designs (plug-and-play connectors, terminal blocks). This segmentation allows rapid module replacement while preserving overall system integrity through standardized interfaces.
Solution Approach 2:
Modules are pre-assembled with all necessary connections, mounting fixtures, and protective housings before installation into the control cabinet. This preliminary preparation enables quick swap-out operations without requiring on-site assembly or complex disassembly procedures.
3Area of stationary object
If power electronic components are integrated in a unified structure, then the device has lower outer dimensions, but replacement requires special tools and trained personnel
Solution Approach 1:
The compact control cabinet structure is maintained while internally organizing components into standardized modules. Each module is designed with uniform dimensions and mounting patterns that fit within the compact enclosure, preserving the small footprint while enabling simple replacement operations.
Solution Approach 2:
Standardized module designs with universal mounting interfaces, connection types, and housing specifications allow the same replacement procedure to be used for different module types (rectifier, inverter, control). This universality enables untrained personnel to perform maintenance using simple tools.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates quick, cost-effective, and environmentally friendly maintenance of ground power units, reducing the need for specialized tools and training, while enhancing user safety and system availability.
Implementation Method 1
at least one rectifier module for converting an input alternating voltage applied to a rectifier module input side into an intermediate direct voltage output at a rectifier module output side
Implementation Method 2
at least one inverter module for converting the intermediate direct voltage applied to an inverter module input side into an output alternating current which is output at an inverter module output side
Data Source
AI summary
A ground power unit provides electrical energy for aircraft and a method maintains and operates the ground power unit. The ground power unit includes a base frame, a cable system formed in the base frame, at least one rectifier module for converting an input alternating voltage applied to a rectifier module input side into an intermediate direct voltage output at a rectifier module output side, wherein the rectifier module output side is coupled to an intermediate circuit conductor and at least one inverter module for converting the intermediate direct voltage applied to an inverter module input side into an output alternating current output at an inverter module output side, wherein the inverter module input side is coupled to an intermediate circuit conductor. The rectifier module and the inverter module are each realized as structurally-independent units, which can be replaced individually and independently of the base frame.