Lightweight DC Common Mode Inductor for Aircraft Motor Controllers
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Solution Overview
Problem
Motor controllers used in aircraft are heavy, which is a design concern as reducing weight improves fuel efficiency and load capacity, and existing solutions with dense materials for common mode and differential mode filters do not adequately address noise interference issues while being lightweight.
Innovation Solution
A motor controller configuration with a common mode filter located on the input side of the inverter and a differential mode filter on the output side, using a direct current common mode inductor with fewer windings to reduce weight, thereby attenuating common and differential mode noise effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional dense materials (copper and steel) are used for inductor windings and magnetic core, then common mode noise attenuation is effective, but the motor controller weight increases significantly
Solution Approach 1:
The patent changes the material parameters of the inductor by using aluminum instead of copper for windings and magnesium or aluminum alloys instead of steel for the magnetic core. This material substitution maintains the electromagnetic functionality while significantly reducing density and weight, directly resolving the contradiction between noise attenuation performance and weight.
Solution Approach 2:
The patent employs composite material construction for the inductor, combining aluminum windings with magnesium or aluminum alloy magnetic core. This composite approach allows optimization of both electromagnetic properties for noise filtering and mechanical properties for weight reduction, achieving a balance between performance and weight requirements.
2Object-affected harmful factors
If the inductor is placed on the output side of the inverter with three separate inductors for each phase, then common mode noise is reduced, but the device complexity and weight increase
Solution Approach 1:
The patent merges three separate phase inductors into a single common mode inductor with a shared magnetic core. The aluminum windings are configured to handle all three phases through the unified magnetic circuit, reducing component count and assembly complexity while maintaining common mode noise attenuation effectiveness.
Solution Approach 2:
The single common mode inductor serves multiple functions: it provides magnetic coupling for all three phases and simultaneously attenuates common mode noise across the entire three-phase system. This multi-functional design replaces what would traditionally require three separate inductors, simplifying the overall device architecture.
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 configuration reduces the weight of the motor controller by approximately 23% while effectively attenuating noise, improving the safety and efficiency of aircraft systems by minimizing noise interference with sensitive electronics.
Implementation Method 1
The common mode inductor is configured to attenuate common mode noise and is located on the input side of the inverter
Data Source
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AI summary
A motor controller has a direct current input, inverter 40, common mode filter 54, differential mode filter 42, and an output terminal. The direct current input is electrically connected to the common mode filter. The common mode filter is electrically connected to the inverter. The inverter is electrically connected in to the differential mode filter. The differential mode filter is electrically connected to the output terminal. The common mode filter is configured to attenuate common mode noise and is located on the input side of the inverter. The differential mode filter attenuates differential mode noise and is located on the output side of the inverter. A motor system having a motor controller, a direct current source, a feeder cable, and an electric motor.