Modular Aircraft Ground Power Unit for Fast Module Replacement
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Solution Overview
Problem
Existing ground power units for aircraft require complex and costly maintenance due to the integration of power electronic components in a single control cabinet, making component changes time-consuming and resource-intensive.
Innovation Solution
A modular design where rectifier and inverter modules are structurally independent, allowing for easy and economical replacement, with identical modules differing only in control software, and featuring plug-in connections and quick-release fasteners for safe and tool-free operation, enabling ergonomic working heights and parallel operation for redundancy and load sharing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If power electronic components are integrated in a single control cabinet, then the unit structure is compact, but component replacement becomes time-consuming and costly
Solution Approach 1:
The control cabinet is divided into modular units, each containing specific power electronic components (rectifier modules, inverter modules). These modules can be independently replaced without dismantling the entire cabinet, thus maintaining structural compactness while enabling easy component replacement.
Solution Approach 2:
Individual power electronic components are extracted from the integrated control cabinet and placed into separate, self-contained modules. This allows defective modules to be removed and replaced as complete units, significantly reducing replacement time and cost while maintaining the overall compact structure.
2Device complexity
If all power electronic components are in one cabinet, then the design is simple, but maintenance requires considerable time and special tools
Solution Approach 1:
The design is segmented into standardized modules that can be quickly swapped out. Each module is designed as a complete functional unit with integrated components, allowing maintenance personnel to replace only the defective module rather than working on the entire cabinet, thus reducing maintenance time while keeping the overall design simple.
Solution Approach 2:
The modules are designed with universal interfaces and standardized mounting mechanisms that work across different module types. This universality allows any module to be replaced with any other compatible module using the same procedure and tools, simplifying the maintenance process while reducing time loss.
3Device complexity
If components are integrated in a single unit, then the structure is compact, but replacement is associated with considerable expense
Solution Approach 1:
By segmenting the system into modular units, each module can be manufactured independently using standardized processes. This reduces manufacturing complexity and cost compared to building a completely integrated unit, while maintaining the compact structural integration of components within each module.
Solution Approach 2:
The modular design allows defective modules to be replaced without wasting the rest of the system. The replaced modules can be recovered, refurbished, and reused, significantly reducing replacement costs compared to replacing components within an integrated structure where the entire unit may need replacement or complex repair.
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
Facilitates quick, cost-effective, and safe maintenance with reduced training requirements, providing an environmentally friendly and resource-efficient ground power unit with increased system availability and flexibility.
Implementation Method 1
at least one rectifier module (8) for converting an input AC voltage (21) applied to a rectifier module input side (20) into an intermediate DC voltage (23) output at a rectifier module output side (22)
Implementation Method 2
at least one inverter module (9) for converting the intermediate DC voltage (23) applied to an inverter module input side (25) into an output AC voltage (27) output at an inverter module output side (26)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a GPU (1) for the provision of electrical energy for aircraft, and to a method for maintaining and operating the GPU according to the invention. The GPU comprises a base, a cable system (4) which is formed in the base, at least one rectifier module (8) for converting an input AC voltage (21) applied on a rectifier-module input side (20) into an intermediate DC voltage (23) leaving on a rectifier-module output side (22), wherein the rectifier-module output side (22) is coupled to a DC-link conductor (24), and at least one inverter module (9) for converting the intermediate DC voltage (23) applied on an inverter-module input side (25) into an output AC voltage (27) leaving on an inverter-module output side (26), wherein the inverter-module input side (25) is coupled to a DC-link conductor (24). Moreover, the rectifier module (8) and the inverter module (9) are each produced as structurally distinct units, which can be replaced individually and independently of the base.