Hybrid Aircraft Engine Clutch Control for Stable Power Changes
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Solution Overview
Problem
Hybrid aircraft power plants face challenges in optimizing architecture to allow independent operation of electric motors and thermal engines, while minimizing parts, reducing production and maintenance costs, and enhancing reliability and weight efficiency.
Innovation Solution
A method for operating a hybrid aircraft power plant with a propeller, electric motor, and thermal engine, utilizing an overrunning clutch and propeller control unit to manage controllable parameters like blade pitch, fuel flow, and electric power, to avoid undesired clutch behavior by modulating these parameters when risks are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the electric motor and thermal engine are allowed to operate independently or simultaneously, then the operational flexibility and power output range are improved, but the system complexity and number of parts increase
Solution Approach 1:
The patent combines the electric motor and thermal engine into a single hybrid power plant system that shares common components such as the propeller, clutch, and control units. This merging allows independent or simultaneous operation of both power sources while reducing overall system complexity through component sharing and integration.
Solution Approach 2:
The hybrid power plant is designed with multi-functional capability where the same system components serve multiple purposes depending on the operational mode. The clutch, propeller, and control units function differently when the electric motor operates alone, when the thermal engine operates alone, or when both operate together, providing operational flexibility without requiring separate dedicated systems for each mode.
2Adaptability or versatility
If more parts are added to enable independent operation of electric motor and thermal engine, then operational modes are improved, but production cost and maintenance cost increase
Solution Approach 1:
The patent merges multiple functional requirements into a unified hybrid power plant architecture where the electric motor, thermal engine, propeller, and control systems are integrated. This consolidation enables multiple operational modes (electric-only, thermal-only, hybrid) while minimizing the total number of distinct parts, thereby reducing production costs and simplifying manufacturing processes.
3Adaptability or versatility
If more parts are added to enable independent operation of electric motor and thermal engine, then operational modes are improved, but maintenance cost increases
Solution Approach 1:
The hybrid power plant integrates the electric motor and thermal engine into a unified system with shared components including the propeller, clutch mechanism, and control units. This merging reduces the total number of parts that require maintenance compared to having separate independent systems, thereby lowering maintenance costs while still enabling multiple operational modes.
Solution Approach 2:
The control unit and other system components are designed to serve multiple operational modes universally. The same control unit manages electric-only mode, thermal-only mode, and hybrid mode, eliminating the need for mode-specific maintenance procedures and reducing overall maintenance complexity and costs.
4Ease of manufacture
If the number of parts is reduced to lower production and maintenance costs, then manufacturing efficiency is improved, but the ability to allow independent operation of electric motor and thermal engine is worsened
Solution Approach 1:
The patent achieves production efficiency by merging the electric motor and thermal engine into a unified hybrid power plant with shared components. Despite the reduced number of parts, the system maintains the capability for independent operation of both power sources through intelligent control of the clutch and power management system, which selectively engages or disengages the thermal engine based on power demands.
5Reliability
If the clutch is kept engaged to prevent undesired behavior, then reliability is improved, but wear on the clutch increases leading to higher maintenance
Solution Approach 1:
The control method dynamically adjusts clutch engagement status based on real-time operational conditions and power demands. The clutch remains engaged during modes requiring thermal engine power transmission but is disengaged when the electric motor operates alone or when the thermal engine is not contributing to power output. This dynamic control prevents unnecessary wear while maintaining reliability when engagement is required.
Solution Approach 2:
The hybrid power plant incorporates a control unit that continuously monitors operational parameters and provides feedback to adjust clutch engagement status. Based on feedback regarding power demands, electric motor output, and thermal engine operation status, the control unit makes real-time decisions about clutch engagement, optimizing both reliability and wear prevention.
Data Source
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AI summary
The method can include operating the hybrid aircraft power plant (110) in a first mode of operation in which a plurality of controllable parameters including a fuel flow to the thermal engine (118) and an electric power to the electric motor (120) has a first set of values corresponding to a first power output; receiving a requested power output; determining a second set of values of the one or more of the controllable parameters to bring first power output to the requested power output; determining whether said second set of values poses a risk of undesired clutch behavior; and when the second set of values poses the risk, modulating the second set of values to avoid the risk and setting the plurality of controllable parameters to the modulated second set of values.