Electric Nacelle Battery Pack Cooling to Limit Failure Propagation
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Solution Overview
Problem
Existing battery power systems for aircraft face challenges in thermal management and the risk of battery cell failure propagation, necessitating improved solutions for efficient thermal management and replaceability.
Innovation Solution
An integrated electric nacelle system that electrically couples a motor to a battery bank with a fluid pathway, incorporating a thermal management system driven by the motor to urge fluid through the pathway, and positions the battery bank, motor, and controller as a line-replaceable unit (LRU) within a nacelle, with heat exchangers between battery packs to enhance cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If lithium-polymer battery cells are used to achieve higher energy density and voltage output, then fewer cells are needed, but thermal management becomes more challenging and risk of cell failure propagation increases
Solution Approach 1:
The battery bank is divided into multiple modular battery packs that can be independently managed and replaced. Each pack is separated into discrete units with individual mounting positions, allowing segmentation of the thermal management challenge into smaller, more manageable zones rather than treating the entire battery bank as a single thermal system.
Solution Approach 2:
The thermal management system is extracted as a separate, dedicated subsystem with its own fluid pathways, heat exchangers, and cooling channels. This independent thermal management infrastructure removes heat directly at the battery pack level before it can propagate, addressing the thermal challenge separately from the electrical energy storage function.
2Quantity of substance
If lithium-polymer battery cells are used to achieve higher energy density, then fewer cells are needed, but the risk of battery cell failure propagating throughout the system increases
Solution Approach 1:
The battery bank is segmented into multiple independent battery packs with separate mounting positions and individual electrical connections. This segmentation creates isolation barriers that prevent failure propagation between packs, as each pack operates as a semi-independent unit with its own thermal and electrical boundaries.
Solution Approach 2:
The controller is extracted as a separate management system that can independently monitor and control each battery pack. This allows for individual pack isolation and management, enabling the system to detect and contain failures at the pack level rather than allowing them to propagate throughout the entire battery bank.
3Volume of moving object
If battery components are integrated into a nacelle, then space is optimized, but maintenance and replaceability become more difficult
Solution Approach 1:
The battery bank is segmented into modular packs that can be independently removed and replaced. Each pack is designed as a discrete unit with standardized mounting positions, allowing maintenance personnel to replace individual faulty packs without disassembling the entire nacelle or battery system, thus maintaining ease of repair while optimizing space utilization.
Solution Approach 2:
The battery packs are designed with universal mounting interfaces and standardized configurations that allow them to be easily installed and removed in the nacelle. This multi-functional design enables the same pack structure to serve both space optimization goals and maintenance requirements, as the standardized interfaces facilitate quick replacement while the compact arrangement optimizes nacelle volume.
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 effectively manages thermal issues, reduces the risk of battery failure propagation, and facilitates easy maintenance by isolating high-energy components, improving safety and operational efficiency.
Implementation Method 1
a thermal management system configured to urge fluid through the fluid pathway
Implementation Method 2
a motor configured to rotate a rotor via a rotor shaft... a controller configured to drive the motor... the motor is configured to drive the thermal management system
Data Source
AI summary
The present disclosure relates to propulsion system for an aircraft. The propulsion system comprises a motor, a battery bank, a thermal management system, and a controller. The motor being configured to rotate a rotor via a rotor shaft and to drive the thermal management system. The thermal management system configured to urge fluid through a fluid pathway defined by the battery bank. The controller configured to drive the motor and/or control charge and discharge of the battery bank.