External Coupling Layout for Maintainable Electric Propulsion Units
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Solution Overview
Problem
Existing propulsion units require frequent maintenance of coupling systems, necessitating the dismantling and removal of the transmission system, which is time-consuming and costly.
Innovation Solution
The coupling system is positioned outside the transmission system, with coupling shafts and a freewheel mechanism allowing for maintenance without disassembling the transmission system, and includes a freewheel that disengages when torque exceeds a threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coupling system is positioned inside the transmission system housing, then the structure is compact and integrated, but maintenance requires dismantling the transmission system which is time-consuming and costly
Solution Approach 1:
The coupling system is segmented from the transmission system by positioning it in a separate accessible location (external mounting or separate compartment) while maintaining functional integration through the coupling shafts that pass through the transmission system housing. This allows independent maintenance of the coupling system without dismantling the transmission system.
Solution Approach 2:
The coupling system is extracted from the internal housing space and positioned externally or in a separately accessible compartment. The coupling shafts maintain the functional connection by passing through the transmission system housing, allowing the coupling system to be maintained independently while preserving the integrated structure.
2Loss of time
If the coupling system is positioned outside the transmission system, then maintenance can be performed without disassembling the transmission system, but the overall system occupies more space
Solution Approach 1:
The coupling system is positioned in a different spatial dimension or location relative to the transmission system, such as externally mounted on the housing or in a separately accessible compartment. The coupling shafts pass through the housing to maintain functional connection, enabling maintenance access without increasing the primary system footprint.
3Reliability
If the coupling system uses a freewheel mechanism for torque threshold protection, then the transmission system is protected from overload, but the coupling system requires more frequent maintenance
Solution Approach 1:
The freewheel mechanism provides automatic overload protection that operates without external intervention. When torque exceeds the threshold, the freewheel automatically disengages to protect the transmission system, and can be reset without complex procedures, reducing the impact of maintenance requirements on productivity.
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
This configuration reduces maintenance time and frequency, maintains transmission system operation during failures, and enhances system compactness and accessibility.
Implementation Method 1
a freewheel which is configured to adopt a coupled state in which the output shaft (34) of the corresponding electric motor (20) is coupled in terms of rotation and transmits a rotational movement to the kinematic chain (26) of the transmission system (22), in addition to an uncoupled state, in the case of a malfunction for example, in which the output shaft (34) of the corresponding electric motor (20) is no longer coupled to the kinematic chain (26) of the transmission system (22) and no longer transmits any rotational movement thereto
Data Source
AI summary
A propulsion unit comprising a propulsion system, at least one electric motor positioned in a first external zone, a transmission system, a coupling device which comprises: a first coupling shaft coupled to an output of the electric motor, passing through the transmission system and having a first end protruding into a second external zone; a second coupling shaft coupled to an input of the transmission system, passing through at least one wall of the transmission system and having a first end protruding into the second external zone; and a coupling system configured to couple the first ends of the first and second coupling shafts in terms of rotation and which is positioned in the second external zone. Also an aircraft having at least one such propulsion unit.