Parallel Motor Controller Architecture for Aircraft Weight Reduction
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Solution Overview
Problem
The existing motor control systems in aircraft and other vehicles are heavy due to the weight of dedicated motor controllers, which are proportional to their power rating, leading to inefficiencies in power distribution and weight reduction challenges.
Innovation Solution
A system of parallel motor controllers connected through a power switching network, dynamically reconfiguring power distribution based on current power demands, allowing multiple smaller controllers to serve multiple motors, reducing the overall weight and power rating requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If dedicated motor controllers are used for each motor with power ratings matching peak demand, then sufficient power delivery is ensured, but system weight increases significantly
Solution Approach 1:
The system divides the motor control function into multiple smaller parallel motor controllers instead of using one large dedicated controller per motor. Each controller in the pool is sized for a fraction of the total power requirement, and controllers are dynamically allocated to motors based on instantaneous power demand. This segmentation allows the system to meet peak power requirements while using lighter individual controller units.
Solution Approach 2:
The patent creates a universal pool of motor controllers that can serve multiple motors interchangeably. Instead of dedicating specific controllers to specific motors, any controller in the pool can be assigned to any motor that requires power. This multi-functionality allows the same set of controllers to handle varying power demands across different motors at different times, reducing the total number of controllers needed.
2Weight of moving object
If multiple smaller motor controllers are used in parallel, then system weight is reduced, but dynamic power distribution complexity increases
Solution Approach 1:
The system implements dynamic allocation of motor controllers to motors based on real-time power demands. The controller assignment is not fixed but changes continuously as motors start, stop, or vary their power requirements. This dynamic approach allows the system to optimize power distribution efficiently while managing complexity through automated control algorithms that respond to changing operational conditions.
Solution Approach 2:
The patent employs feedback mechanisms where the control system continuously monitors the power demands of motors and the availability of controllers in the pool. Based on this feedback, the system automatically adjusts controller assignments to match current power requirements. This closed-loop control manages the complexity of dynamic power distribution by using real-time information to make optimized allocation decisions without requiring complex pre-planning.
3Power
If motor controllers are sized for peak power demand, then maximum power output is ensured, but weight increases proportionally
Solution Approach 1:
The patent merges multiple smaller motor controllers into a unified power pool that collectively provides the maximum power output capability. Instead of each controller being sized for peak demand of a single motor, several smaller controllers are combined so their aggregate capacity equals the total peak power requirement of all motors. This merging allows the system to achieve the same maximum power output while using lighter individual controller units.
Solution Approach 2:
The system changes the power rating parameter of individual motor controllers from being sized for peak single-motor demand to being sized for a fraction of total system demand. By adjusting this parameter and using multiple controllers in parallel, the system maintains the same maximum power output capability while reducing the weight of each individual controller unit, since controller weight is proportional to its power rating.
Data Source
AI summary
A method for real time power control over a plurality of motor controllers by at least one processor on a computer system may include determining a power load demand from a first set of motors, selecting a combination of motor controllers to match the power load demand, assigning a first set of system-wide priorities, configuring a power switching network to connect the first set of motors to the motor controllers, receiving from a control unit a power request for a motor, determining a priority designation for that motor, assigning a second set of system-wide priorities, determining a second power load demand from a second set of motors, wherein the second plurality of active motors comprises the first plurality of active motors and the first motor, selecting a second combination of motor controllers necessary to match the second power load demand, and configuring the power switching network in accordance with the second set of system-wide priorities.