Axially Stacked Motor Modules With Clutch for VTOL Propulsion
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Solution Overview
Problem
Conventional propulsion systems for air vehicles, particularly VTOL types, face challenges such as uncontrolled crashes due to 'dead man's curve' issues and high power requirements that change during development or operational life cycles, leading to costly redesigns and performance reductions.
Innovation Solution
A propulsion system assembly featuring axially stacked electric motor modules with a clutch arrangement that allows for selective coupling and decoupling, providing a safety margin and efficient power distribution, enabling the air vehicle to maintain operation even with module failures and adapt to changing power demands without full engine shutdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional propulsion systems are used for VTOL air vehicles, then high power requirements can be met, but the system becomes vulnerable to uncontrolled crashes due to dead man's curve issues and lacks redundancy
Solution Approach 1:
The propulsion system is divided into multiple independent electric motor modules (first module, second module, third module, fourth module) that can operate independently. Each module can be selectively engaged or disengaged from the common driveshaft, allowing the system to maintain functionality even when individual modules fail, thereby resolving the contradiction between reliability and complexity.
Solution Approach 2:
The system employs dynamic engagement and disengagement of motor modules through clutch mechanisms. The number of active modules can be adjusted in real-time based on power requirements and operational conditions, enabling the system to adapt between high-power VTOL mode (multiple modules engaged) and lower-power aerodynamic flight mode (fewer modules engaged), thus resolving the reliability-complexity contradiction.
2Reliability
If the number of electric motor modules is increased to provide redundancy and overcome dead man's curve, then reliability improves, but cost of ownership and device complexity increase significantly
Solution Approach 1:
Multiple electric motor modules share a common driveshaft and rotor assembly, creating a universal propulsion architecture. The same physical components (driveshaft, rotor, transmission) serve all motor modules, meaning that adding redundancy through additional modules does not proportionally increase overall system complexity or cost, as the shared components are counted only once.
3Adaptability or versatility
If the propulsion system is redesigned to meet changing power demands during development or operational life cycle, then power requirements are satisfied, but time, effort, and resources increase
Solution Approach 1:
The system allows dynamic adjustment of the number of engaged motor modules to match changing power demands. During high-power phases (VTOL, hover), more modules are engaged; during lower-power phases (aerodynamic flight), fewer modules are engaged. This dynamic reconfiguration capability eliminates the need for physical redesign, resolving the contradiction between adaptability and redesign time.
Solution Approach 2:
The modular architecture with independently controllable motor modules enables flexible reconfiguration of power output. The system can selectively engage or disengage modules based on operational requirements, providing adaptability without requiring complete system redesign, thus resolving the contradiction between versatility and redesign time.
4Power
If all electric motor modules operate at maximum power, then high thrust is achieved for VTOL, but power consumption and system stress increase
Solution Approach 1:
The system employs partial action by engaging only the necessary number of motor modules required to meet current power demands. During aerodynamic flight, fewer modules are engaged compared to VTOL operations, avoiding excessive power consumption while maintaining sufficient thrust output. This resolves the contradiction between achieving high thrust and minimizing energy use.
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
The system ensures air vehicle survival and efficient operation by allowing continued thrust with reduced modules, providing weight savings and improved performance, and enabling efficient power usage across different flight phases without the need for frequent engine redesigns.
Implementation Method 1
The clutch arrangement for the respective electric motor module comprises a clutch rotor and a field coil concentrically provided on the rotor element, and an armature affixed to the drive shaft. Responsive to actuation of the clutch arrangement, the clutch rotor may frictionally abut the armature drive shaft to enable transmission of torque between the respective electric motor module and the drive shaft.
Data Source
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AI summary
A propulsion system assembly is provided including a driveshaft and a plurality of electric motor modules. The driveshaft is rotatably mounted to a casing about a drive axis, the driveshaft including a first shaft end and an opposite facing second shaft end. The plurality of electric motor modules are in axially stacked relationship with one another with respect to the drive axis to define an electric motor module stack, each electric motor module being configured for transmitting a torque to the driveshaft when coupled thereto independently of at least one other electric motor module. Each electric motor module includes a controllable clutch arrangement for selectively coupling and decoupling the respective electric motor module with respect to the driveshaft to respectively enable and disable transmission of torque between the respective electric motor module and the driveshaft.