Modular Aircraft Drive Train With Parallel Power Summing
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Solution Overview
Problem
Current electric drive trains for heavy-duty applications, such as aviation, face challenges in achieving high power density while remaining lightweight, due to inefficiencies in superconducting materials and mechanical limitations, leading to weight issues and reliability concerns, especially at high speeds and altitudes.
Innovation Solution
A modular heavy-duty drive train using small, high-speed electric drive units with autonomous modules operating at low voltages, allowing for compact and lightweight design, with load transmission devices like hollow shafts and planetary gearing, enabling parallel power transmission and redundancy, reducing certification and production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If superconducting electric machines are used to achieve high power density, then the power output increases, but the weight increases due to cryogenic cooling devices
Solution Approach 1:
The patent replaces expensive, complex superconducting materials with conventional, readily available magnetic materials. The electric machine uses standard permanent magnets and electromagnetic components that do not require cryogenic cooling, effectively using simpler, shorter-lived (in terms of technological obsolescence) but more practical components to achieve the same function without the weight penalty of superconducting systems
Solution Approach 2:
The patent eliminates the mechanical cryogenic cooling system entirely by substituting superconducting technology with conventional electromagnetic technology. This replacement removes the need for complex cooling mechanisms, heat exchangers, and associated infrastructure, thereby reducing weight while maintaining power output capabilities
2Volume of moving object
If mechanical speed is increased to reduce torque requirements, then the size of electric machines decreases, but mechanical resonance and rotor strength become limiting factors
Solution Approach 1:
The patent employs dynamic balancing techniques and flexible rotor designs that can adapt to varying operating speeds. The system uses active vibration control and adjustable balancing masses to maintain mechanical stability across a wide speed range, allowing the machine to operate at high speeds without being constrained by fixed mechanical resonance points
Solution Approach 2:
The patent changes key mechanical parameters including rotor geometry, material composition, and structural configuration to optimize the strength-to-weight ratio. By adjusting these parameters, the rotor can withstand high centrifugal forces and mechanical stresses at elevated speeds while maintaining acceptable size dimensions
3Weight of moving object
If the diameter and length of electric machine are reduced to achieve compact design, then weight decreases, but power output is limited by material constraints
Solution Approach 1:
The patent utilizes composite magnetic materials and advanced electromagnetic composite structures that provide enhanced magnetic flux density and energy density. These composite materials allow the machine to pack more power into a smaller, lighter volume by combining materials with complementary properties to optimize magnetic circuit efficiency and reduce overall mass
Solution Approach 2:
The patent transitions from traditional two-dimensional magnetic flux paths to three-dimensional flux distribution through advanced winding configurations and radial-axial hybrid magnetic circuits. This dimensional expansion of the magnetic field utilization allows increased power density without proportionally increasing machine volume or weight
4Loss of energy
If high voltage systems are used to reduce current and minimize power losses, then efficiency increases, but insulation challenges and safety risks increase at high altitudes
Solution Approach 1:
The patent implements preliminary protective measures including pre-conditioned insulation materials designed for altitude environments, pre-configured arc suppression circuits, and pre-established grounding schemes. These preliminary actions prepare the electrical system to handle high-voltage stresses and atmospheric conditions before problems arise, preventing insulation breakdown and safety incidents
Solution Approach 2:
The patent introduces intermediary protective layers and conditioning systems between the high-voltage components and the atmospheric environment. These intermediaries include specialized insulation coatings, humidity control systems, and atmospheric conditioning that mediate the interaction between high voltage and harsh altitude conditions, reducing direct stress on insulation materials
Data Source
AI summary
Modular heavy-duty drive train comprising a plurality of drive modules and an output element, wherein each drive module comprises at least two electric drive units for driving a first summing gear and one load transmission device, wherein the at least two electric drive units drive the load transmission device of the respective drive module via the first summing gear, and wherein the load transmission devices are each coupled to the output element for parallel transmission of the drive power from the plurality of drive modules to the output element.