eVTOL Gearbox and Main Shaft Layout for Low-Noise Reliability
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Solution Overview
Problem
Conventional aircraft driven by electric propulsion systems face challenges in frequent use, noise reduction, vibration management, and safety, particularly in densely populated areas, with a need for components that withstand frequent flights, generate low noise, and have redundancy to avoid single points of failure.
Innovation Solution
The development of a distributed electric propulsion system with tiltable electric engines that can transition between vertical and horizontal flight, using a combination of forward and aft engines to optimize energy density, reduce weight, and incorporate fire protective barriers to minimize risk, along with advanced cooling and lubrication systems to reduce noise and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional aircraft components are used, then manufacturing and operation are simpler, but they wear out quickly and cannot withstand frequent use
Solution Approach 1:
The aircraft propulsion system is divided into multiple independent electric engines (distributed propulsion) rather than using a single conventional engine. Each engine operates independently, allowing the system to withstand frequent use better as individual components can be maintained or replaced without shutting down the entire system.
Solution Approach 2:
Fire protective barriers are installed around engine components before operation to prevent catastrophic failure. These barriers provide advance protection against potential fires or explosions, allowing the system to operate more reliably under frequent use conditions without the risk of complete system failure.
2Productivity
If high power engines are used to enable frequent flights, then flight frequency increases, but noise and vibration increase
Solution Approach 1:
The total propulsion requirement is divided across multiple smaller electric engines rather than using fewer high-power engines. This segmentation distributes the noise and vibration sources throughout the aircraft, preventing concentration of harmful effects in one location and allowing higher overall productivity without excessive noise or vibration at any single point.
Solution Approach 2:
Conventional mechanical engines are replaced with electric engines that drive propellers. This substitution eliminates the combustion process and mechanical transmission systems that generate significant noise and vibration, allowing the aircraft to operate frequently without generating harmful noise and vibration levels.
3Reliability
If distributed propulsion system is used to avoid single point of failure, then safety improves, but system complexity increases
Solution Approach 1:
The propulsion system is segmented into multiple independent electric engine units, each with its own control systems. This modular segmentation provides redundancy (improving safety) while keeping each individual unit relatively simple, allowing the overall system to achieve high reliability without excessive complexity in any single component.
Solution Approach 2:
The distributed electric propulsion system serves multiple functions simultaneously: it provides thrust, enables vertical takeoff and landing, allows for tilt-rotor operation, and provides inherent redundancy for safety. This multi-functionality reduces the need for separate systems, thereby managing complexity while improving reliability.
4Use of energy by moving object
If electric engines with high voltage power are used, then energy density increases, but heat generation increases
Solution Approach 1:
The high-voltage power system is divided into multiple separate electric engine units, each handling a portion of the total power requirement. This segmentation distributes heat generation across multiple locations rather than concentrating it in a single engine, making thermal management more effective while maintaining high energy density at the system level.
Solution Approach 2:
Heat exchangers are introduced as intermediary components between the electric engines and the surrounding environment. These heat exchangers efficiently transfer heat away from the high-voltage power systems, allowing the engines to operate at high energy density without excessive temperature buildup.
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 eVTOL aircraft, allowing for frequent flights with reduced noise and vibration, enhanced safety through redundancy, and compliance with aviation regulations.
Implementation Method 1
The electric engine may include a cooling system that may include a fluid flow path that may be coupled to an outlet and an inlet, respectively, of bores or grooves that may be present on a rotor
Implementation Method 2
The electric engine may include a lubrication system that may include a fluid flow path that may be coupled to an outlet and an inlet, respectively, of bores or grooves that may be present on a rotor
Data Source
AI summary
An electric engine for a vertical takeoff-and-landing aircraft comprising an electric motor assembly including a stator and a rotor. The electric engine may comprise an inverter assembly, a gearbox assembly including a sun gear, and a main shaft including a length of the main shaft that extends from a first end of the main shaft through the gearbox assembly and through the electric motor assembly to a second end of the main shaft. The electric engine may include a hydrodynamic bearing located between the main shaft and sun gear, and a bearing including an inner race mechanically coupled to the main shaft and an outer race mechanically coupled to the rotor. The electric engine may include a bearing including an outer race mechanically coupled to an inner surface of the rotor.