Planetary Gearbox Pump Drive for eVTOL Propulsion Cooling
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Solution Overview
Problem
Conventional aircraft propulsion systems face challenges in frequent, short-duration flights over densely populated areas, requiring components that withstand wear, generate low noise and vibration, manage heat, and ensure safety with distributed propulsion to avoid single points of failure, while meeting aviation regulations and operating efficiently in restricted spaces.
Innovation Solution
The aircraft is designed with a distributed electric propulsion system featuring multiple electric engines mounted forward and aft of the wings, capable of tilting for vertical and horizontal thrust, optimized for energy density, and incorporating fire protective barriers to minimize oil use, reducing weight and drag, and incorporating redundancy to prevent single points of failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional aircraft propulsion systems are used, then the system structure is simple, but the components wear out quickly during frequent flights and generate excessive noise and vibration
Solution Approach 1:
The patent replaces the conventional mechanical reciprocating engine system with an electric propulsion system consisting of electric motors and planetary gearboxes. This substitution eliminates the pistons, valves, and combustion mechanisms that generate noise and vibration, while providing smoother operation and greater reliability for frequent flights.
Solution Approach 2:
The patent changes the operating parameters by using electric motors that can precisely control rotation speed and torque, unlike conventional engines. The planetary gearbox enables variable gear ratios to optimize performance across different flight phases, reducing mechanical stress and wear while minimizing noise and vibration generation.
2Reliability
If distributed propulsion system with multiple electric engines is implemented, then safety is improved by avoiding single point of failure, but system complexity increases
Solution Approach 1:
The patent divides the propulsion system into multiple independent electric engine modules distributed across the aircraft structure. Each module contains its own motor and planetary gearbox, creating redundant propulsion units. This segmentation ensures that failure of one module does not compromise the entire propulsion system, while the modular design actually simplifies maintenance and replacement procedures.
3Object-affected harmful factors
If fire protective barriers are incorporated to minimize oil use, then fire safety is improved, but aircraft weight increases
Solution Approach 1:
The patent extracts and eliminates the fire hazard by removing the oil lubrication system entirely from the planetary gearboxes. Instead of using oil that requires fire protective barriers, the system employs dry lubrication or solid lubricant materials, thereby eliminating the need for heavy fire protection structures while maintaining safety.
4Power
If planetary gearbox assembly is used in electric engines, then torque transmission efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent optimizes the planetary gearbox design by adjusting gear ratios, planet gear counts, and carrier configurations to achieve high torque transmission with relaxed tolerance requirements. The design incorporates floating elements and compliant mounting structures that accommodate manufacturing variations, thereby maintaining high efficiency without requiring extreme manufacturing precision.
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
The system enhances safety, efficiency, and compliance with aviation regulations by minimizing noise, vibration, and weight, while ensuring reliable operation and reduced risk of fire, enabling vertical takeoff and landing in restricted spaces.
Implementation Method 1
a planetary gear assembly (1020) having a sun gear (1006), a ring gear (1024), and a plurality of planetary gears (1018) positioned between the sun gear (1006) and the ring gear (1024)
Implementation Method 2
The sun gear (1006) may be mechanically coupled to the rotor (1008), and the ring gear (1024) may be fixed to the motor-gearbox assembly housing (1002A)
Implementation Method 3
The gearbox assembly (1010) may include a pinion gear (1022) in mesh with a gear (1028) on the propeller shaft (1030)
Implementation Method 4
The gearbox assembly (1010) may include a pinion gear (1022) in mesh with a gear (1028) on the propeller shaft (1030). The propeller shaft (1030) may extend through the sun gear (1006) and may be mechanically coupled to the carrier (1020).
Data Source
AI summary
An electric propulsion system for a vertical take-off and landing (VTOL) aircraft having a heat exchanger to cool fluids used in an electrical engine, the electric propulsion system comprising at least one electrical engine mechanically connected directly or indirectly to a fuselage of the VTOL aircraft and electrically connected to an electrical power source. The electrical engine may comprise an electrical motor having a stator and a rotor; a gearbox assembly comprising a sun gear; at least one planetary gear; a ring gear; and a planetary carrier. The electric engine may include an inverter assembly comprising a thermal plate and an inverter assembly housing; an end bell assembly that is connected to the thermal plate of the inverter assembly; and a heat exchanger comprising an array of cooling fins and tubes.