Multi-mode Generator for Aircraft Ice Protection
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Solution Overview
Problem
Existing electric Wing Ice Protection Systems (eWIPS) are complex, heavy, and costly, with full-power pulsing causing excessive wear on engine gearboxes due to torque pulses, and backup generators are redundant and unused.
Innovation Solution
Operation of multi-mode generators in variable voltage mode for eWIPS during ice formation conditions and fixed voltage mode as backup power when main generators fail, reducing torque pulses and utilizing backup generators for flight operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If full-power pulsing is applied to eWIPS zones, then ice protection effectiveness is improved, but torque pulses cause excessive wear on engine gearbox
Solution Approach 1:
The generator operates in two dynamic modes: variable voltage mode for eWIPS operation and fixed voltage mode for backup power. The system dynamically transitions between these modes based on operational requirements, allowing full-power pulsing for ice protection while using the backup generator to absorb torque pulse effects during normal eWIPS operation.
Solution Approach 2:
The multi-mode generator acts as an intermediary between the engine gearbox and the eWIPS system. By introducing this intermediate power conversion device, the system can deliver high-power pulses to eWIPS without directly transmitting torque pulses to the engine gearbox, thus protecting the gearbox from excessive wear.
2Reliability
If backup generator is installed for ETOPS compliance, then flight safety is improved, but generator remains unused and adds weight
Solution Approach 1:
The backup generator is designed with multi-functionality: it serves as a standby power source for ETOPS compliance while simultaneously being capable of supporting eWIPS operation in variable voltage mode. This dual-purpose design ensures the backup generator is utilized during normal operations, reducing its effective weight penalty since it is no longer completely redundant.
Solution Approach 2:
The generator's operating parameters are changed based on mode requirements. In variable voltage mode, it operates with adjustable voltage output for eWIPS; in fixed voltage mode, it provides stable backup power. This parameter flexibility allows the same hardware to fulfill multiple functions, optimizing the weight-to-functionality ratio.
3Object-generated harmful factors
If variable voltage is used for eWIPS, then torque pulses are reduced, but system complexity increases
Solution Approach 1:
The generator control system implements dynamic voltage adjustment capability, transitioning between fixed and variable voltage modes based on operational requirements. This dynamic control reduces torque pulses during eWIPS operation while maintaining simplicity through mode-based control logic rather than continuous complex regulation.
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 approach reduces gearbox wear, minimizes fuel consumption, and utilizes backup generators for flight safety without the need for extensive wiring and heavy components.
Implementation Method 1
The engines also drive integral generators, which generate electricity at a fixed voltage level
Implementation Method 2
Anti-ice systems include applying heat, either electrical or from engine bleed air
Data Source
AI summary
On an aircraft, a multi-mode power generator is operated in a variable voltage mode to power an electric Wng Ice Prevention System (eWIPS), and is operated in a fixed voltage mode to provide backup power. When atmospheric conditions are conducive to the formation of ice (and main generators are operative), the multi-mode power generator is operated in variable voltage mode to power the eWIPS with a first or second variable voltage. The first variable voltage, the value of which depends on atmospheric conditions, is for anti-ice operation. The second variable voltage, which can be the maximum output voltage, is for de-ice operation. Transitions between different variable voltage levels are not instantaneous which eliminates fatigue damage due to transients. If a main generator fails (or when atmospheric conditions are not conducive to the formation of ice), the multi-mode power generator is operated in fixed voltage mode to provide backup power.