Electric Propulsion System With Dual-Flow Stator Cooling
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Solution Overview
Problem
Existing flight vehicles, such as drones, face challenges in efficiently providing lift and propulsion while effectively cooling the electric components of their propulsion systems, particularly the stator coils, which generate heat during operation.
Innovation Solution
The implementation of an electric rim-driven fan system with a stator and rotor configuration, combined with a heat exchanger within the airflow passage to cool the stator coils, and a coolant system to manage heat generation, resulting in a more compact and efficient propulsion system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heat exchanger is added to cool the stator coils, then the cooling effectiveness is improved, but the device complexity increases
Solution Approach 1:
The heat exchanger is integrated with the existing airflow passage structure, merging the cooling function into the propulsion system's airflow path rather than adding a completely separate cooling system. This reduces overall device complexity while achieving effective stator coil cooling.
Solution Approach 2:
The airflow passage serves multiple functions: it provides thrust by moving air through the propulsion system and simultaneously serves as a cooling channel for the stator coils. This multi-functionality eliminates the need for dedicated cooling passages, reducing device complexity.
2Temperature
If a coolant system is implemented to cool the stator coils, then the thermal management is improved, but the device complexity increases
Solution Approach 1:
The system uses its own operational airflow to provide cooling for the stator coils, rather than requiring an external or separate cooling system. The airflow that is already present for propulsion purposes is directed through the heat exchanger to cool the coils, making the system self-sufficient and reducing overall complexity.
3Volume of moving object
If the airflow passage is designed to provide both thrust and cooling, then the system compactness is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The airflow passage is divided into distinct functional zones: a first portion dedicated to thrust generation and a second portion configured for cooling the stator coils. This segmentation allows each zone to be optimized for its specific function while maintaining overall system compactness, and may simplify manufacturing by allowing modular fabrication and assembly.
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 provides enhanced cooling for the stator coils, maintaining system efficiency and compactness, while ensuring equivalent lift and thrust forces are maintained through balanced airflow design.
Implementation Method 1
a heat exchanger within the airflow passage to cool the stator coils
Implementation Method 2
an electric drive mechanism arranged to drive the fan rotor assembly about the fan centerline axis
Data Source
AI summary
An electric propulsion system includes a fan rotor assembly having a first fan portion and a second fan portion. A fan cowling defines a first flow passage and a second flow passage. An electric drive mechanism drives the fan rotor assembly. An electric drive cooling system includes a liquid coolant that provides cooling to at least a part of the electric drive mechanism, and a heat exchanger through which the liquid coolant flows is arranged within the second flow passage. The first fan portion provides a first flow of air through the first flow passage to provide at least one of a lifting force or a thrust force to the electric propulsion system, and the second fan portion provides a second flow of air through the second flow passage to provide a flow of cooling air therethrough that is in thermal communication with the heat exchanger.