Aircraft Electric Propulsion Gearbox Layout for Power-Loss Reliability
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Solution Overview
Problem
Existing electric aircraft propulsion systems face challenges in optimizing component layout within limited space and ensuring reliability and efficiency, particularly during power failures.
Innovation Solution
Aircraft propulsion systems incorporating a gearbox module, electric motor assembly, and propulsor with offset gears and accessory loads, allowing for compact design and redundancy to maintain operation during power failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a compact layout is implemented to optimize space utilization, then space efficiency is improved, but system reliability may deteriorate due to limited space for redundant components
Solution Approach 1:
The patent implements a nested configuration where the accessory load assembly is positioned within the motor assembly's axial space. The accessory load assembly includes a shaft aligned with the motor's rotational axis, allowing accessories to be mounted in the central region while the stator and rotor occupy the outer regions. This nesting approach maximizes space utilization without compromising reliability.
Solution Approach 2:
The patent transitions from a traditional lateral arrangement of components to an axial arrangement along the motor's rotational axis. By positioning the accessory load assembly axially coincident with the motor assembly and using a shaft aligned with the rotational axis, the design efficiently utilizes the third dimension (axial direction) to achieve compact layout while maintaining adequate space for reliable operation.
2Reliability
If redundant components are added to ensure operation during power failures, then system reliability is improved, but device complexity increases
Solution Approach 1:
The motor assembly serves multiple functions: it provides primary propulsion during normal operation and simultaneously acts as a generator during power failures. The accessory load assembly, driven by the motor's rotational energy, can power essential accessories even when external power is lost. This multi-functionality approach enhances reliability without adding separate redundant systems.
Solution Approach 2:
The system uses its own kinetic energy from the rotating propeller to generate electricity during power failures. The accessory load assembly is driven by the motor's rotor inertia and can generate electrical power through electromagnetic induction, allowing the system to service itself during emergencies without external power sources or complex backup systems.
3Temperature
If accessory loads are positioned away from the motor assembly for better heat dissipation, then thermal management is improved, but space efficiency deteriorates
Solution Approach 1:
The accessory load assembly is nested within the axial space of the motor assembly, with its shaft aligned with the motor's rotational axis. This nested configuration allows heat to dissipate axially along the shaft and radially through the motor housing, providing effective thermal management without requiring separate lateral space for heat sinks or cooling components.
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 efficient use of limited space and enhances system reliability by enabling continued operation of accessory loads even during power failures, improving overall propulsion system performance.
Implementation Method 1
The electric motor includes a rotor. The rotor is mounted to a first offset gear of the plurality of offset gears. The rotor is configured for rotation about a rotational axis to drive rotation of the gear assembly and the output shaft.
Data Source
AI summary
An assembly for a propulsion system of an aircraft includes a gearbox module, an electric motor assembly, a first accessory load assembly, and a propulsor. The gearbox module includes a gear assembly and an output shaft. The gear assembly includes a main gear and a plurality of offset gears. The electric motor assembly includes an electric motor. The electric motor includes a rotor. The rotor is mounted to a first offset gear of the plurality of offset gears. The rotor is configured for rotation about a rotational axis to drive rotation of the gear assembly and the output shaft. The first accessory load assembly includes at least one first accessory load. The at least one first accessory load is mounted to a second offset gear of the plurality of offset gears. The propulsor is coupled to the output shaft.