Integrated Rotor Fan Assembly for Aircraft Motor Cooling
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Solution Overview
Problem
Traditional electric motors for aircraft applications face challenges in minimizing weight while maintaining high power density and efficiency, particularly due to the weight burden of dense permanent magnets, and require advanced cooling solutions to manage thermal limitations effectively.
Innovation Solution
The design incorporates a rotor assembly with an outer and inner diameter portion, an end portion, and a fan assembly that induces cooling flow through the stator cavity, along with a compact thermal management system using lightweight materials and non-magnetic structures with embedded magnetic wires to reduce torque ripple and weight, while integrating fan assemblies for enhanced airflow and heat extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If dense permanent magnets are used to maximize magnetic loading, then torque density is improved, but weight increases
Solution Approach 1:
The patent combines the cooling fan function with the rotor structure by integrating fan blades into the rotor body, eliminating the need for separate cooling components and reducing overall weight while maintaining high magnetic loading for torque density
2Temperature
If advanced cooling solutions are implemented, then thermal management is improved, but device complexity increases
Solution Approach 1:
The rotor serves its own cooling needs by incorporating fan blades directly into its structure, allowing the rotating component to generate its own cooling airflow without requiring external cooling systems or additional complexity
Solution Approach 2:
The cooling function is merged with the rotor structure itself, combining two functions (rotation and cooling) into a single integrated component, thereby reducing overall system complexity
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 achieves reduced weight, improved thermal and power efficiency, and increased power density by effectively managing thermal loads and minimizing torque ripple, enabling efficient operation under varying aircraft power conditions.
Implementation Method 1
at least one fan assembly arranged in the rotor assembly and configured to induce a cooling flow through the stator cavity
Data Source
Figure 1A~1B
Figure 2A
Figure 2B
AI summary
An aircraft electric motor includes a rotor assembly (500) having an outer diameter portion (502), an inner diameter portion (504), and an end portion (506), arranged to define a stator cavity (534), and a rotor hub (510) configured to connect to a shaft of the aircraft electric motor, a stator assembly arranged within the stator cavity (534), and at least one fan assembly (530,532) arranged in the rotor assembly (500) and configured to induce a cooling flow through the stator cavity (534).