eVTOL Inverter Assembly Layout for Cooling and Redundant Propulsion
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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 heat, and have redundancy to avoid single points of failure.
Innovation Solution
The development of a distributed electric propulsion system with tiltable electric engines, a DC to AC inverter assembly, and a fire protective barrier to minimize noise, vibration, and heat generation, while ensuring safety through redundancy and efficient lubrication and cooling, allowing for both vertical and conventional takeoff and landing capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electric propulsion components are used, then the system is simpler and easier to manufacture, but the components wear out quickly during frequent use and generate excessive heat and noise
Solution Approach 1:
The propulsion system is divided into multiple independent distributed electric engines rather than using a single conventional propulsion system. Each engine operates independently with its own inverter assembly and cooling system, allowing the system to withstand frequent use without component wear affecting the entire system. This segmentation enables individual component replacement and maintenance without grounding the entire aircraft.
Solution Approach 2:
The electric engines are made tiltable rather than fixed, allowing dynamic adjustment of thrust direction. This dynamic capability enables the same propulsion system to perform both vertical takeoff/landing and conventional horizontal flight, increasing versatility without requiring separate propulsion systems for different flight modes.
2Temperature
If conventional inverter assemblies are used, then the design is simpler, but they generate excessive heat and noise during operation
Solution Approach 1:
The inverter assembly is merged with the electric engine into a single integrated unit rather than being a separate component. This consolidation allows the inverter to be positioned directly within the engine housing where it can utilize the engine's existing cooling airflow paths, significantly reducing heat generation without requiring separate cooling systems. The merged design also reduces noise by eliminating additional mounting structures and connections.
Solution Approach 2:
A heat exchanger is introduced as an intermediary component between the inverter assembly and the external environment. The heat exchanger efficiently transfers heat from the inverter to the cooling airflow passing through the engine, enabling effective heat dissipation while keeping the inverter assembly compact and easily manufacturable.
3Reliability
If distributed propulsion system is implemented, then safety is improved through redundancy, but the system complexity and weight increase
Solution Approach 1:
Each distributed electric engine is designed as a universal module that can perform multiple functions: vertical lift generation, horizontal thrust production, and emergency backup for other engines. This multi-functionality allows the system to achieve safety redundancy without proportionally increasing weight, as each engine contributes to multiple safety margins rather than requiring dedicated backup systems.
Solution Approach 2:
The number of distributed electric engines is optimized to provide sufficient redundancy while controlling weight. Rather than using an excessive number of engines, the system uses a carefully calculated minimum number that provides the required safety margin according to aviation regulations, balancing redundancy benefits against weight penalties.
4Adaptability or versatility
If tiltable electric engines are used, then both vertical and conventional takeoff are enabled, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The electric engines are mounted on tiltable mechanisms rather than fixed rigid mounts. This dynamic mounting allows the same engine assembly to be oriented for vertical takeoff or conventional horizontal takeoff as needed. The tilting mechanism uses simple hydraulic or electric actuators that are easier to manufacture than completely separate vertical and horizontal propulsion systems.
Solution Approach 2:
A single universal engine design with tilting capability replaces the need for different specialized engines for vertical and conventional takeoff. This universal design simplifies manufacturing by standardizing engine components, mounting structures, and control systems across all propulsion units, rather than maintaining separate manufacturing lines for different engine types.
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 drag, and enhanced safety features, meeting regulatory requirements and improving passenger comfort.
Implementation Method 1
DC to AC conversion by an inverter assembly to allow more powerful AC motors
Implementation Method 2
electric engines of the distributed electric propulsion system, which may include the necessary components to convert the high voltage electrical power into mechanical shaft power
Implementation Method 3
a fire protective barrier to minimize noise, vibration, and heat generation, while ensuring safety through redundancy and efficient lubrication and cooling
Data Source
AI summary
An electrical propulsion system for a vertical take-off and landing (VTOL) aircraft comprises an electrical motor assembly and an inverter assembly. The inverter assembly comprises a housing, a capacitor assembly, at least one printed circuit board assembly (PCBA), and a plurality of positioning pins. The capacitor assembly comprises a center hole, at least one capacitor, a capacitor housing having at least one busbar, and a plurality of through holes in the capacitor housing. The capacitor assembly and the at least one PCBA are positioned inside the housing. The plurality of positioning pins pass through the through the plurality of through holes of the capacitor housing and the at least one PCBA and are connected to the housing.