eVTOL End Bell Thermal Plate Cooling for Electric Propulsion Heat
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Solution Overview
Problem
Conventional aircraft driven by electric propulsion systems face challenges in frequent use, noise reduction, vibration management, heat generation, and safety, particularly in densely populated areas, with a need for components that withstand wear and tear while minimizing noise, vibration, and heat, and ensuring safety through distributed propulsion systems.
Innovation Solution
The development of a tilt-rotor aircraft with a distributed electric propulsion system that includes multiple electric engines mounted forward and aft of the wing, capable of vertical and conventional takeoff and landing, with a heat exchanger for cooling and a fire protective barrier to prevent uncontained fires, utilizing a gearbox assembly and inverter system for efficient energy conversion and lubrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If electric engines are used in aircraft propulsion systems, then energy efficiency is improved, but heat generation increases
Solution Approach 1:
A thermal plate is introduced as an intermediary component between the electric engine and the heat exchanger. The thermal plate conducts heat away from the electric engine, serving as a heat transfer medium that enables efficient thermal management while maintaining the energy efficiency benefits of electric propulsion
Solution Approach 2:
A heat exchanger using fluid circulation is implemented to cool the thermal plate. The coolant fluid absorbs heat from the thermal plate and dissipates it externally, providing continuous heat removal to manage the heat generation from electric engines during operation
2Productivity
If components are designed for frequent use, then productivity is improved, but wear and tear increases
Solution Approach 1:
The gearbox assembly incorporates self-lubricating features where the lubrication system is integrated into the gearbox structure itself. This self-service lubrication mechanism continuously reduces friction and wear on gear components, enabling the gearbox to withstand frequent operational cycles without degradation
Solution Approach 2:
The lubrication parameters are optimized by adjusting viscosity and flow characteristics of the lubricant to match the high-frequency operational demands. This parameter optimization reduces friction coefficients and thermal buildup, allowing the components to endure frequent use while maintaining reliability
3Reliability
If fire protective barriers are added to prevent uncontained fires, then safety is improved, but device complexity increases
Solution Approach 1:
The fire protective barrier is merged with the existing engine housing structure rather than being added as a separate component. The housing is designed with fire-resistant materials and structural features that simultaneously provide mechanical protection and fire containment, reducing overall system complexity while maintaining safety
Solution Approach 2:
Fire-resistant composite materials are used in the engine housing and barrier structures. These materials combine structural integrity with fire protection properties, allowing the housing to serve dual functions of mechanical support and fire containment without adding significant complexity
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
The solution enables efficient, safe, and quiet operation of electric propulsion systems in aircraft, reducing noise and vibration, enhancing safety through redundancy and minimizing heat generation, while allowing for efficient energy use and compliance with aviation regulations.
Implementation Method 1
a heat exchanger for cooling
Implementation Method 2
an end bell assembly connected to a thermal plate
Data Source
AI summary
An electric propulsion system for a vertical take-off and landing (VTOL) aircraft having a heat exchanger to cool fluids used in an electrical engine, the electric propulsion system comprising at least one electrical engine mechanically connected directly or indirectly to a fuselage of the VTOL aircraft and electrically connected to an electrical power source. The electrical engine may comprise an electrical motor having a stator and a rotor; a gearbox assembly comprising a sun gear; at least one planetary gear; a ring gear; and a planetary carrier. The electric engine may include an inverter assembly comprising a thermal plate and an inverter assembly housing; an end bell assembly that is connected to the thermal plate of the inverter assembly; and a heat exchanger comprising an array of cooling fins and tubes.