Integrated Polyphase Drive Layout for Compact Cooling and Power Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing solutions for integrating power electronics with polyphase electrical machines in aircraft and rotorcrafts face issues of low compactness, thermal constraints, and volume limitations, particularly in aeronautical applications, where radial surface integration is not feasible and internal integration poses thermal and volume challenges.
Innovation Solution
A hybrid integrated variable-speed drive architecture for polyphase electrical machines, where power electronics are both internal and external to the casing, featuring a single annular DC bus decoupling capacitor and modular power electronics distribution, along with a coolant circuit using U-shaped tubes for efficient cooling, ensuring improved heat extraction and temperature strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If power electronics are integrated internally within the casing, then compactness is improved, but thermal constraints and volume limitations worsen
Solution Approach 1:
The power electronics are segmented into multiple modular units distributed around the inner circumference of the casing extension. This segmentation allows heat to be distributed across multiple cooling zones rather than concentrated in a single location, enabling effective thermal management while maintaining high volumetric power density.
Solution Approach 2:
The power electronic modules are nested within the casing extension, with the coolant circuit nested around them. The U-shaped tubes are positioned to surround the power modules, creating a nested configuration where cooling is integrated directly around the heat-generating components without requiring separate thermal management space.
2Temperature
If power electronics are integrated externally on the radial surface, then thermal management is improved, but compactness worsens
Solution Approach 1:
Instead of integrating power electronics radially on the outer surface (2D surface integration), the invention moves them to the inner circumference of a longitudinal extension (3D volumetric integration). This dimensional transition allows the cooling system to surround the power modules from multiple directions, improving heat extraction while maintaining compact overall dimensions.
3Temperature
If power electronics are integrated externally at the axial end, then thermal management is improved, but adaptability worsens due to space availability constraints
Solution Approach 1:
The casing extension with distributed power modules and U-shaped coolant tubes creates a universal configuration that can be adapted to various application requirements. The modular power electronics can be adjusted in number and arrangement, and the coolant circuit can be configured to provide optimal cooling, making the design versatile for different power levels and thermal management needs.
4Adaptability or versatility
If multiple separate capacitors are used for each power module, then modularity is improved, but volume increases
Solution Approach 1:
Instead of using separate capacitors for each power module, the invention merges them into a single annular decoupling capacitor that surrounds the entire set of power modules. This single capacitor serves all modules simultaneously, maintaining the benefits of modular power electronics while dramatically reducing the total volume required for energy storage components.
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 significantly increases volumetric power density, enhances thermal management, and improves mechanical strength, reliability, and fault tolerance, addressing the limitations of existing solutions by optimizing compactness and performance.
Implementation Method 1
a coolant is introduced at a first end of said U-shaped tubes through a radial inlet orifice disposed at a free end of said longitudinal casing extension and extracted at a second end of said U-shaped tubes
Implementation Method 2
the use of a single annular decoupling capacitor and of the modular disposition of the power electronics in an extension of the casing significantly increases the volumetric power density while solving the problem posed by the large volume of this type of components
Data Source
AI summary
Polyphase electrical machine with n phases, n≥3, including a casing defining a longitudinal axis, a stator and a rotor including a mechanical drive shaft, the electrical machine being equipped with a power electronics and a coolant circuit and the power electronics is formed of n power electronic modules evenly distributed over an inner circumference of a longitudinal extension of the casing whose outer circumference is covered with a single annular DC bus decoupling capacitor electrically connected to the n power electronic modules, the coolant circuit including a plurality of U-shaped tubes with a tubular outgoing part extending over an entire length of the casing and including the longitudinal casing extension and a shorter tubular return part, extending over a casing length excluding the longitudinal casing extension.