Hybrid Rotorcraft Powertrain Torque Monitoring for Gearbox Protection
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Solution Overview
Problem
Existing systems fail to effectively monitor and protect the gearbox in hybrid power plants of rotorcrafts from excessive torque when both the heat engine and electric motor operate simultaneously, leading to potential damage.
Innovation Solution
A monitoring system that includes sensing devices to measure torque and a controller to manage reversible transmission devices, such as clutches or electric switches, to prevent excessive torque from being transmitted to the gearbox, ensuring the torque remains within predetermined limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the heat engine and electric motor operate simultaneously to provide combined power, then the power output and productivity are improved, but the torque may exceed the gearbox limits and cause damage
Solution Approach 1:
The system performs preliminary actions by pre-calculating torque distribution coefficients and storing torque limit values in memory before excessive torque occurs. The controller continuously monitors torque and compares it against pre-stored limits, enabling proactive protection rather than reactive response.
Solution Approach 2:
The system implements feedback by continuously measuring actual torque with sensing devices, comparing it against limit values stored in memory, and using the controller to adjust the reversible transmission device accordingly. This closed-loop control ensures torque remains within safe limits while maximizing power output.
2Reliability
If the torque limit is strictly enforced to protect the gearbox, then the reliability is improved, but the power transmission capability is reduced
Solution Approach 1:
The system applies dynamics by making the torque transmission adaptive rather than fixed. The reversible transmission device dynamically adjusts its state based on real-time torque conditions, allowing full power transmission when safe and blocking only when necessary to prevent exceeding limits.
Solution Approach 2:
The system changes the parameter of torque transmission by using the reversible transmission device to modulate the actual torque delivered to the gearbox. The controller adjusts the transmission state based on the relationship between current torque and stored limit values, optimizing power transmission within safety constraints.
3Reliability
If a monitoring and control system is added to manage torque, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The controller performs multiple functions within a single device: it stores torque limit values, receives torque measurements, compares actual torque against limits, and controls the reversible transmission device. This multi-functionality reduces overall system complexity by consolidating control tasks.
Solution Approach 2:
The reversible transmission device acts as an intermediary between the power sources and the gearbox. It simplifies the control architecture by providing a single control point that manages torque transmission, shielding the gearbox from direct exposure to excessive torque while allowing full power transmission when safe.
Data Source
AI summary
A monitoring system for monitoring a hybrid power plant of a rotorcraft comprising at least one rotor. The hybrid power plant has an electric motor comprising a first drive shaft, a heat engine comprising a second drive shaft and a gearbox. The monitoring system includes at least one first sensing device measuring a first item of torque information representative of a first engine torque C1 transmitted by the first drive shaft to a first input shaft of the gearbox and a controller comparing the first engine torque C1 with a first limit value VL1.