Electric Aircraft Rotor Coupling as Load-Bearing Power Conductor
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Solution Overview
Problem
The weight of electric aircrafts, such as eVTOLs, is increased due to the need for large cross-sectional area wirings from the battery to the electric motors, necessitating a reduction in weight.
Innovation Solution
Integrate rigid conductors into the coupling structures that support the rotors, which also serve as wirings, eliminating the need for separate copper wires and utilizing materials like aluminum or copper for these conductors to reduce weight and electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large cross-sectional area wirings are used to supply current from battery to electric motors, then the current supply capability is improved, but the weight of the aircraft increases
Solution Approach 1:
The patent merges the structural support function and electrical conduction function into a single integrated component. The coupling structure that mechanically connects the rotor to the fuselage is designed to also serve as the wiring for current supply. This eliminates the need for separate copper wires, reducing weight while maintaining both structural integrity and electrical conductivity for high current supply.
Solution Approach 2:
The coupling structure is designed with multi-functionality, serving both as a mechanical support element and an electrical conductor. By making the coupling structure itself conductive and capable of carrying high current, the invention eliminates the need for dedicated wiring, thereby reducing overall aircraft weight while maintaining adequate power supply to motors.
2Reliability
If separate copper wires are used for current supply, then the electrical connection is reliable, but the assembly complexity and labor increase
Solution Approach 1:
The patent combines the structural coupling function and electrical wiring function into a single integrated component. The coupling structure that mechanically attaches the rotor to the fuselage is designed to simultaneously serve as the current-carrying conductor, eliminating the need for separate wire laying and connection processes.
Solution Approach 2:
The coupling structure is designed to perform multiple functions: mechanical support, load transmission, and electrical conduction. This multi-functionality simplifies the overall system by reducing the number of components and assembly steps, while maintaining reliable electrical connection through the integrated design.
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
Reduces the weight of the aircraft by eliminating the need for separate copper wires and optimizing the cross-sectional area for both structural support and current flow, thereby enhancing lift generation and reducing assembly labor.
Implementation Method 1
The wirings electrically couples the battery to the at least one electric motor. At least a part of the wirings includes rigid conductors. At least a part of the at least one coupling structure includes the rigid conductors.
Implementation Method 2
At least a part of a load on the fuselage from the at least one rotor is received with the rigid conductors.
Data Source
AI summary
An electric aircraft includes a fuselage, at least one rotor, at least one coupling structure, at least one electric motor, a battery and wirings. The at least one coupling structure couples the at least one rotor to the fuselage. The at least one electric motor is for rotating the at least one rotor. The battery is attached to the fuselage. The battery is for supplying current to the at least one electric motor. The wirings electrically couples the battery to the at least one electric motor. At least a part of the wirings includes rigid conductors. At least a part of the at least one coupling structure includes the rigid conductors. At least a part of a load on the fuselage from the at least one rotor is received with the rigid conductors.