Hybrid Propulsion Controller Updates for Replaceable Aircraft Batteries

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Solution Overview

Problem

Aircraft batteries have a limited life expectancy of two to three years due to degradation, necessitating frequent replacement, which is inefficient compared to the aircraft's thirty-year service life, and their performance decreases over time.

Innovation Solution

A hybrid propulsion control system that includes a controller with a tuning parameters storage unit and optimization algorithms to manage replaceable batteries, allowing for repeated replacement and updates with next-generation batteries, optimizing performance through updated tuning parameters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If replaceable batteries are used in hybrid electric aircraft, then the aircraft can operate with modular power storage that can be replaced, but the battery performance decreases over time and requires frequent replacement every two to three years

Engineering Contradiction:
Improvebattery replaceabilityVSAvoidbattery performance stability
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

The system changes the tuning parameters in the controller to match the characteristics of different battery types. When a battery is replaced, the controller receives updated tuning parameters that optimize performance for the new battery, allowing the system to adapt to parameter changes in the power storage component without performance degradation

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The system dynamically adapts to battery replacements by updating control parameters. The controller is designed to receive and implement new tuning parameters when batteries are replaced, making the system dynamic and adaptable rather than static, thereby maintaining optimal performance across different battery lifecycles

Inventive Principle:
Principle #15Dynamics

2Reliability

If batteries are replaced every two to three years, then performance can be maintained, but this creates inefficiency compared to the aircraft's thirty-year service life and increases operational costs

Engineering Contradiction:
Improvebattery performanceVSAvoidoperational efficiency
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The controller is designed with universal adaptability to work with multiple generations of batteries. By incorporating a updating mechanism that accepts new tuning parameters, the same controller hardware can support both older and next-generation batteries, making the control system multi-functional and extending its useful life alongside the aircraft

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

Solution Approach 2:

The system prepares for battery upgrades in advance by maintaining the capability to receive and implement updated tuning parameters. This preliminary preparation ensures that when next-generation batteries are introduced, the controller is already configured to optimize performance, eliminating downtime and reconfiguration delays

Inventive Principle:
Principle #10Preliminary action

3Quantity of substance

If next-generation batteries with higher energy density are introduced, then battery capacity and range can be improved, but the controller must be updated to optimize performance with the new battery characteristics

Engineering Contradiction:
Improvebattery energy capacityVSAvoidcontroller update mechanism
Core Design Contradiction:
Quantity of substanceVSDevice complexity

Solution Approach 1:

The system replaces physical controller hardware modifications with software-based tuning parameter updates. Instead of redesigning or replacing the entire controller when batteries are upgraded, the system uses digital parameter updates to adapt to new battery characteristics, substituting mechanical redesign with software configuration

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12370909B2Hybrid propulsion control system update module
Publication Date: 2025.07.29 RTX CORP
  • US12370909B2 patent drawing
  • US12370909B2 patent drawing
  • US12370909B2 patent drawing

AI summary

A hybrid propulsion update system includes a controller in signal communication with a replaceable battery. The controller includes a tuning parameters storage unit configured to store at least one tuning parameter corresponding to the replaceable battery. The controller is configured to execute at least one optimization algorithm that utilizes the tuning parameters to control operation of the hybrid electric aircraft according to a first performance. The tuning parameters storage unit is configured to receive at least one updated tuning parameter from a controller updating device. The controller executes the at least one optimization algorithm that utilizes the at least one updated tuning parameter such that the hybrid electric aircraft operates according to a second performance that improves upon the first performance.