Aircraft High-Voltage Wiring Thermal Control Under Peak Current
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Solution Overview
Problem
High voltage wiring in aircraft overheating due to varying current demands poses a risk of wire melting and fire, and oversizing the wiring to prevent overheating adds weight and reduces flight performance.
Innovation Solution
Monitoring high voltage wiring temperature and controlling electric propulsion units based on aircraft state to adjust current draw and predict overheating, using battery pack states to reduce current through the wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the diameter of high voltage wiring is increased to avoid overheating, then the temperature safety is improved, but the aircraft weight increases
Solution Approach 1:
The patent applies dynamics by making the wiring configuration adaptive rather than static. The system dynamically adjusts the effective wiring size and thermal management based on real-time operating conditions, transitioning between different thermal states and cooling modes to optimize both temperature safety and weight efficiency.
Solution Approach 2:
The system changes physical parameters of the wiring system dynamically, including thermal conductivity, effective cross-sectional area, and operating temperature limits, based on real-time monitoring of current, temperature, and environmental conditions. This allows the same physical wiring to safely operate across varying load conditions without requiring oversized dimensions.
2Power
If high current is maintained to meet power demands, then the power delivery is improved, but the high voltage wiring temperature increases risking wire melting and fire
Solution Approach 1:
The patent implements a closed-loop feedback system that continuously monitors wiring temperature, current draw, and environmental conditions. The system uses this feedback to dynamically adjust power delivery limits, cooling activation, and thermal management strategies, ensuring power demands are met while preventing temperature from reaching dangerous levels.
Solution Approach 2:
The system introduces thermal management intermediaries including cooling systems, thermal barriers, and temperature-regulating mechanisms that act between the high current flow and the wiring structure. These intermediaries absorb or dissipate excess heat, allowing high current operation without directly transferring all thermal energy to the wiring insulation.
3Temperature
If the high voltage wiring size is increased to prevent overheating, then the temperature limit compliance is improved, but the flight range and cargo capacity are reduced
Solution Approach 1:
The system dynamically optimizes the wiring configuration and thermal management based on actual flight conditions, transitioning between different operational modes. This allows the aircraft to use smaller, lighter wiring that complies with temperature limits under normal conditions while maintaining the capability to handle peak loads through active thermal management rather than static oversizing.
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
Prevents overheating without increasing wiring size, maintaining aircraft performance and safety by dynamically managing current through the high voltage wiring.
Implementation Method 1
receiving first sensor data indicating at least one attribute of high voltage wiring of the aircraft
Implementation Method 2
The high voltage wiring temperature increases with an increase in current
Implementation Method 3
controlling at least one electric propulsion unit of the aircraft to avoid exceeding the temperature limit
Data Source
Figure 1
Figure 2A~2F
Figure 3
AI summary
The present disclosure relates generally to controlling an aircraft to avoid overheating components. In one embodiment, a method is disclosed, comprising: receiving first sensor data indicating at least one attribute of high voltage wiring of the aircraft; receiving a state of operation of the aircraft; determining a proximity of a temperature of the high voltage wiring to a temperature limit based on the first sensor data and the state of operation of the aircraft; and controlling at least one electric propulsion unit of the aircraft to avoid exceeding the temperature limit based on the determined proximity.