Polyphase Inverter Layout With Shared Cooling and Phase Redundancy

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Solution Overview

Problem

Existing aircraft systems for generating alternating voltage at a fixed frequency from mechanical energy are costly and prone to reliability issues due to mechanical complexity, leading to high maintenance costs and frequent replacements.

Innovation Solution

A compact inverter device comprising multiple single-phase inverters with toroidal output inductors and a radial cooling channel, allowing for efficient cooling and thermal integration, which converts direct voltage into polyphase alternating voltage at a predetermined frequency, with partial availability in case of inverter failure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a traditional generator system with mechanical coupling and rectifier is used, then alternating voltage can be generated from mechanical energy, but the device becomes bulky and requires installation outside the nacelle

Engineering Contradiction:

Improveinverter volumeVSAvoidinstallation location

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The inverter is divided into multiple independent single-phase inverters (first, second, and third single-phase inverters), each capable of operating autonomously. This segmentation allows compact packaging while maintaining functionality, enabling installation within the nacelle volume.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple single-phase inverters are combined into a single integrated device that can deliver polyphase alternating voltage. The shared cooling channel and support structure merge the individual components into a compact unit suitable for nacelle installation.

Inventive Principle:

Principle #5Merging (Combining)

2Temperature

If water cooling is used for the inverter, then thermal management is achieved, but the system becomes more complex and requires additional cooling infrastructure

Engineering Contradiction:

Improveinverter coolingVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling channels of multiple single-phase inverters are merged into a single shared cooling channel. This reduces the overall cooling system complexity and infrastructure requirements while effectively managing thermal loads from all inverters through a unified cooling pathway.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If a single inverter is used, then the system is simpler, but the inverter becomes unavailable as soon as a power switch fails

Engineering Contradiction:

Improveinverter availabilityVSAvoidinverter architecture

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The inverter system is segmented into multiple independent single-phase inverters with separate power switches for each phase. This segmentation ensures that a failure in one inverter does not affect the others, maintaining system availability through functional independence of each phase inverter.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from a single inverter configuration to a multi-inverter configuration, changing the architectural parameter from unity to plurality. This parameter change enables continued operation with reduced capacity rather than complete failure, improving reliability through redundancy.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If traditional mechanical coupling is used between generator and inverter, then power transmission is achieved, but the mechanical complexity leads to high maintenance costs and regular replacement

Engineering Contradiction:

Improvesystem reliabilityVSAvoidmaintenance cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical coupling systems with direct electrical coupling between the generator and the inverter device. This substitution eliminates complex mechanical transmission components (gears, belts, couplings) that require maintenance, thereby improving reliability and reducing maintenance costs through a simplified electrical connection architecture.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution reduces maintenance costs, enhances reliability, and allows for efficient thermal and mechanical integration within the aircraft nacelle, enabling continuous operation even if one inverter fails.

Implementation Method 1

a cooling liquid is intended to circulate along the x axis

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

electronic components of the inverter device are mounted on the support around the cooling channel so as to be able to be cooled by the cooling liquid

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3917301B1Inverter device

Publication Date: 2023.11.08 THALES SA

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AI summary

Inverter device (OD) intended to convert a three-phase DC voltage into a polyphase AC voltage at a predetermined frequency, the inverter device (OD) comprising three single-phase inverters (O1, O2, O3), each of the three single-phase inverters (O1, O2, O3) being capable of delivering one of the three phases.