eVTOL Power Supply Control for Engine Stall Prevention

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Solution Overview

Problem

Existing power supply systems in electric vertical take-off and landing aircraft (eVTOL) face issues with engine stalling during the transition from battery-assisted startup to self-sustaining operation due to loss of generator torque assistance after transistor cutoff.

Innovation Solution

A power supply system with a management controller that performs stall prevention control by setting engine and generator torque command values to maintain a regenerative state, ensuring the generator continues to assist the engine even after the transistor is turned off.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the transistor is turned off to achieve battery-assisted startup, then the battery can assist the engine startup, but the generator torque assistance is lost causing engine stalling

Engineering Contradiction:
Improvebattery assistance for engine startupVSAvoidengine stalling
Core Design Contradiction:
Use of energy by moving objectVSReliability

Solution Approach 1:

The control method prepares the engine and generator torque command values in advance to maintain regenerative state before the transistor is turned off. By setting the generator torque command value to maintain regenerative braking, the system ensures continuous generator assistance even after battery disconnection, preventing engine stalling during the transition to self-sustaining operation

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system changes the operational state of the generator from power generation mode to regenerative braking mode by adjusting the generator torque command value. This parameter change allows the generator to absorb energy and provide continuous torque assistance to the engine, maintaining stability after the transistor cutoff

Inventive Principle:
Principle #35Parameter changes

2Reliability

If the generator is brought into regenerative state to prevent engine stalling, then engine stability is maintained, but the system complexity increases

Engineering Contradiction:
Improveengine stabilityVSAvoidcontrol system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The generator serves multiple functions: it can operate in power generation mode during normal operation and switch to regenerative braking mode for engine stability. This multi-functionality allows a single device to handle both power production and engine support, reducing the need for additional components while maintaining engine stability

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The generator provides self-service by maintaining regenerative state to assist its own engine operation. The system uses the generator's inherent capability to absorb and release energy to stabilize the engine, eliminating the need for external intervention or additional control mechanisms

Inventive Principle:
Principle #25Self-service

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

Prevents engine stalling by maintaining generator assistance, allowing smooth transition to idling state post-transistor cutoff, thereby ensuring stable engine operation.

Implementation Method 1

a generator configured to generate electric power by being driven by the engine

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a power control unit configured to convert alternating current electric power output from the generator into direct current electric power

Methodology Applied
Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Implementation Method 3

the management controller executes stall prevention control for preventing the engine from stalling by setting the engine torque command value and the generator torque command value so as to bring the generator into a regenerative state

Methodology Applied
Scientific EffectRegenerative braking: Electromagnetic Induction

Data Source

PatentUS20250304273A1Power supply system, moving object, and control method of power supply system
Publication Date: 2025.10.02 HONDA MOTOR CO LTD
  • US20250304273A1 patent drawing
  • US20250304273A1 patent drawing
  • US20250304273A1 patent drawing

AI summary

In a power supply system, in a case where a target output electric power of a generator that generates electric power by being driven by an engine is 0 [kW], stall prevention control is executed in which an engine torque command value and a generator torque command value are determined so that the generator is brought into a regenerative state.