eVTOL Gearbox Assembly With Planetary Sets for Quiet Redundancy
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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 tilt-rotor capabilities, optimized energy density, and safety features such as fire protective barriers, along with a gearbox assembly and propeller configurations that allow for vertical and conventional takeoff and landing, and efficient lubrication and cooling using minimal oil, to enhance performance and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional aircraft components are used in electric propulsion systems, then the system can be simpler and lighter, but the components wear out quickly under frequent use and generate excessive heat and vibration
Solution Approach 1:
The gearbox is divided into multiple independent planetary gear sets arranged in series, where each gear set handles a portion of the torque transmission. This segmentation allows individual gear sets to be replaced if worn, while others continue to function, thereby extending system lifespan and maintaining reliability under frequent use.
Solution Approach 2:
The patent incorporates redundant gear sets that serve as backup components. If one gear set fails or wears out, the redundant sets continue to provide torque transmission, cushioning against complete system failure and maintaining operational reliability during frequent flights.
2Power
If high power electric engines are used to enable vertical and conventional takeoff, then thrust capability is improved, but noise and vibration increase in densely populated areas
Solution Approach 1:
The propulsion system uses multiple distributed electric engines rather than a single large engine. Each engine operates at lower power levels, generating less noise and vibration individually, while collectively providing the required thrust for vertical and conventional takeoff. This segmentation of power sources reduces harmful emissions to surrounding areas.
Solution Approach 2:
The system dynamically adjusts the number and power output of active engines based on flight phase and thrust requirements. During vertical takeoff, all engines operate at high power; during cruise, fewer engines operate at lower power, reducing noise and vibration when full thrust is not needed, thereby minimizing harmful effects in populated areas.
3Reliability
If distributed propulsion system with multiple engines is implemented, then safety redundancy is improved, but device complexity increases
Solution Approach 1:
Each electric engine in the distributed propulsion system is designed as a universal, interchangeable unit that can perform all propulsion functions. The engines share common design specifications, control systems, and maintenance requirements, which reduces overall system complexity despite having multiple units. This universality allows any engine to replace another, maintaining safety redundancy without proportionally increasing complexity.
Solution Approach 2:
The distributed propulsion system uses identical or homogeneous engine units throughout, rather than different specialized engines. This homogeneity simplifies the control architecture, maintenance procedures, and spare parts inventory, reducing device complexity while maintaining the safety benefits of having multiple redundant propulsion units.
4Reliability
If gearbox assembly with multiple planetary gear sets is used, then torque transmission and reliability are improved, but weight and volume increase
Solution Approach 1:
Multiple planetary gear sets are merged into a single integrated gearbox assembly sharing common housings, bearings, and lubrication systems. This combining approach achieves the reliability benefits of redundant gear sets while minimizing weight and volume by eliminating duplicate support structures and systems that would exist if the gear sets were separate assemblies.
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 densely populated areas, with reduced weight and noise, and improved redundancy to minimize failure risks, meeting stringent aviation regulations.
Implementation Method 1
a first set of planetary gears mechanically coupled to the rotor such that rotation of the rotor rotates the first set of planetary gears, a second set of planetary gears mechanically coupled to the first set of planetary gears such that rotation of the first set of planetary gears rotates the second set of planetary gears
Implementation Method 2
The gearbox assembly may include an oil reservoir that may be in communication with the planetary gears such that the planetary gears are lubricated by the oil in the oil reservoir
Implementation Method 3
The gearbox assembly may include an oil reservoir that may be in communication with the planetary gears such that the planetary gears are cooled by the oil in the oil reservoir
Data Source
AI summary
An electric propulsion system for a vertical take-off and landing (VTOL) aircraft, the electric propulsion system including an electrical motor having a stator and a rotor. The electric propulsion system may include a main shaft possessing at least one shoulder on an outer surface of the main shaft. The electric propulsion system may include a gearbox assembly comprising a sun gear that is concentrically aligned with the main shaft at least one planetary gear that interfaces with the sun gear. The electric propulsion system may include a planetary carrier, wherein a center of the planetary carrier is concentrically aligned with the main shaft. The electric propulsion system may include a propeller flange assembly that travels through the rotor, and an axial buttress positioned in the at least one shoulder located on the main shaft.