Decoupled Six-Phase Smart Motor for VTOL
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Solution Overview
Problem
Current electric motors in VTOL aircraft lack the power-to-weight ratio and reliability due to the presence of a gearbox, which increases maintenance and reduces efficiency, and existing configurations fail to provide electrical and magnetic isolation between windings, limiting their operational flexibility.
Innovation Solution
A smart motor design featuring a permanent magnet synchronous machine with two sets of three-phase star-connected windings that are magnetically and electrically decoupled, eliminating interphase inductances and allowing independent operation of each set in case of a breakdown, without a gearbox, and incorporating a ring gear and Halbach array magnets for enhanced torque and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a gearbox is added to increase power output, then the power capability is improved, but the reliability deteriorates and maintenance operations increase
Solution Approach 1:
The patent replaces the mechanical gearbox transmission system with an electrical power multiplication approach using multiple independent winding sets (first and second three-phase assemblies) that can be independently controlled by separate inverters. This substitution eliminates mechanical gears, shafts, and associated components, thereby improving reliability while maintaining the capability to deliver high torque and power output through electrical means.
2Ease of manufacture
If multiple windings are electrically coupled with a common neutral conductor to reduce production cost, then the manufacturing cost is reduced, but electrical and magnetic isolation between winding groups is lost
Solution Approach 1:
The patent segments the electrical system into completely independent first and second three-phase winding assemblies, each with its own neutral conductor and dedicated inverter. This segmentation creates electrical and magnetic isolation between the two sets of windings, allowing independent operation and control. The system can operate with one or both sets depending on operational needs or failure conditions, providing enhanced adaptability and operational flexibility while maintaining manufacturing feasibility through modular construction.
3Power
If the number of electric motors is increased to achieve required power output, then the power capability is improved, but the mass and volume of the propulsion assembly increase
Solution Approach 1:
The patent merges multiple power generation capabilities into a single integrated motor structure by incorporating both first and second three-phase winding assemblies on the same stator core, sharing common magnetic circuits and structural components. This consolidation achieves the power output of what would otherwise require multiple separate motors while significantly reducing the overall mass and volume of the propulsion assembly through component sharing and spatial integration.
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 design enhances the power-to-weight ratio, reliability, and maintenance efficiency by enabling the motor to operate in degraded modes and reduces volume and mass, while ensuring mechanical torque provision in case of inverter or stator failures.
Implementation Method 1
a permanent magnet synchronous machine including one or two permanent magnet rotor(s) and at least one six-phase stator per rotor endowed with at least two three-phase assemblies each formed from three windings electrically coupled in a star
Implementation Method 2
the synchronous machine including one or two permanent magnet rotor(s) and at least one six-phase stator per rotor endowed with at least two three-phase assemblies
Implementation Method 3
incorporating a ring gear and Halbach array magnets for enhanced torque and reduced size
Data Source
AI summary
A smart motor having a permanent magnet synchronous machine and an electronic control unit, the synchronous machine including one or two permanent magnet rotor(s) and at least one six-phase stator per rotor endowed with at least two three-phase assemblies each formed of three windings electrically coupled in a star, the electronic control unit including one control inverter per stator equipped with six independent arms each configured to control one phase of a six-phase stator. The three-phase assemblies are magnetically and electrically decoupled with respect to one another.