Integrated Electric Propulsion Assembly for eVTOL Weight Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electric multi-propulsion systems, such as eVTOL aircraft, face challenges with volumetric, gravimetric, and thermal constraints that limit efficient flight performance due to the design and assembly of propulsor units.
Innovation Solution
An integrated electric propulsion assembly is designed, comprising a stator with a first magnetic element and a propulsor with an integrated rotor, where the rotor's hub is rotatably mounted and features a second magnetic element generating a varying magnetic field, allowing for magnetic force interaction and rotation, thereby reducing weight and drag while enabling efficient thrust generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If propulsor units are designed with separate motor and propeller components, then the system is easier to manufacture and maintain, but the weight and volumetric occupancy increase, reducing flight efficiency
Solution Approach 1:
The patent merges the motor and propeller into a single integrated propulsor unit where the motor housing forms part of the propeller assembly. The motor shaft is directly coupled to the propeller hub, eliminating the need for separate mounting brackets, shafts, and fasteners. This integration reduces overall weight while maintaining manufacturing feasibility through modular assembly processes.
Solution Approach 2:
The motor housing serves multiple functions: it acts as the motor casing, the propeller mounting structure, and part of the aerodynamic fairing. The integrated design allows the same components to fulfill both structural and aerodynamic roles, reducing the total number of parts needed while keeping the design manufacturable through standard fabrication processes.
2Weight of moving object
If propulsor components are integrated into structural elements, then weight and drag are reduced, but installation and maintenance become more difficult
Solution Approach 1:
The integrated propulsor is designed with segmented, modular components that can be detached from the aircraft structure. The propeller assembly can be removed as a unit from the motor housing, and the motor can be separated from the aircraft mounting structure. This segmentation allows for easy removal and replacement of individual components for maintenance while maintaining the integrated design benefits during operation.
3Use of energy by moving object
If magnetic elements are used for thrust generation, then energy efficiency is improved, but thermal issues arise due to magnetic field variations
Solution Approach 1:
The patent introduces a magnetic flux distributor as an intermediary component between the magnetic elements and the thrust generation zone. This distributor evenly distributes the magnetic flux across the air gap, preventing localized magnetic saturation and reducing eddy current losses. The result is more uniform heat distribution that is easier to manage while maintaining the energy efficiency benefits of magnetic thrust generation.
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 design reduces weight and drag, enhances energy efficiency, and allows for longer flight times by integrating the propulsion components into structural elements, facilitating easier installation, maintenance, and cooling, while minimizing thermal issues.
Implementation Method 1
the at least a first magnetic field and the at least a second magnetic field further comprises a varying magnetic field that varies with respect to time. generating a magnetic force between the at least a first magnetic element and the at least a second magnetic element; and the magnetic force causes the hub to rotate with respect to the stator
Implementation Method 2
at least a first magnetic element generating a first magnetic field and a propulsor with an integrated rotor. The propulsor further comprises a hub rotatably mounted to the stator and at least a second magnetic element affixed to the hub. The at least a second magnetic element generating a second magnetic field
Data Source
AI summary
An integrated electric propulsion assembly includes a stator including at least a first magnetic element generating first magnetic field. The assembly includes a propulsor with an integrated rotor, the propulsor further including a hub rotatably mounted to the stator and at least a second magnetic element affixed to the hub, the at least a second magnetic element generating a second magnetic field. At least one of the first magnetic field and the second magnetic field varies with respect to time, wherein the varied magnetic field includes generating a magnetic force between the at least a first magnetic element and the at least a second magnetic element, and the magnetic force causes the hub to rotate with respect to the stator.