Bidirectional Converter Switching for Hybrid Aircraft Electric Machines

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Solution Overview

Problem

Existing hybrid aircraft propulsion systems face inefficiencies due to the need for multiple independent converters for electric machines, leading to increased weight, cost, and complexity, as well as reduced reliability.

Innovation Solution

A bidirectional motor controller unit (MCU) is used to selectively couple generators and motors, incorporating inverters and rectifiers, allowing for a single MCU to manage multiple electric machines by switching between different operating conditions, reducing the need for multiple converters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple independent converters are used for electric machines in hybrid aircraft propulsion systems, then each machine can be independently controlled, but the system weight, cost, and complexity increase

Engineering Contradiction:

Improveindependent control capabilityVSAvoidnumber of converters

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements a single bidirectional converter that can serve multiple electric machines (generators and motors) by using switching devices to selectively connect different machines to the converter. This multi-functional approach allows one converter to replace what would traditionally require multiple independent converters, thereby reducing system weight, cost, and complexity while maintaining the ability to independently control each machine through electronic switching

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If multiple independent converters are used for electric machines, then each converter can be optimized for its specific function, but the overall system reliability decreases due to more failure points

Engineering Contradiction:

Improveconverter optimizationVSAvoidsystem reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

By consolidating multiple converters into a single bidirectional converter that can be electronically configured for different functions, the system reduces the total number of potential failure points. The switching devices enable the same hardware to be optimized for different operating modes (generation or motor operation) without requiring separate dedicated converters for each function, thus improving reliability while maintaining functional optimization

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If a single bidirectional converter is used to manage multiple electric machines, then system weight and cost are reduced, but the switching control complexity increases

Engineering Contradiction:

Improvenumber of convertersVSAvoidswitching control

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The patent introduces switching devices as intermediaries between the single bidirectional converter and multiple electric machines. These switching devices act as mediators that electronically connect or disconnect specific machines from the converter based on operational requirements. This intermediary layer manages the control complexity by providing a standardized interface and automated switching logic, making the system easier to operate despite the multifunctional nature of the converter

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This approach simplifies the propulsion system by reducing weight and cost while enhancing reliability through a single converter that can switch between power generation and motor operation, improving efficiency and reducing the need for redundant components.

Implementation Method 1

a bidirectional motor controller unit (MCU) is used to selectively couple generators and motors, incorporating inverters and rectifiers

Methodology Applied

Scientific EffectInversion (electrical):

Implementation Method 2

incorporating inverters and rectifiers, allowing for a single MCU to manage multiple electric machines

Methodology Applied

Scientific EffectRectification:

Data Source

PatentUS12451769B2Multiplexed bi directional converters for hybrid electric aircraft propulsion

Publication Date: 2025.10.21 HAMILTON SUNDSTRAND CORP

AI summary

A system includes a low pressure machine, a high pressure machine, a motor controller device, a first set of switches configured to selectively couple the low pressure machine to an inverter or a rectifier included in the motor controller device, based on a control signal, and a second set of switches configured to selectively couple the high pressure machine to the inverter or the rectifier, based on the control signal.