Integrated Power Electronics Layout for Compact Polyphase Machines
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Solution Overview
Problem
Existing solutions for integrating power electronics with polyphase electric machines in aircraft and rotorcraft face challenges in compactness, thermal management, and compatibility, particularly due to radial surface integration issues and axial integration constraints.
Innovation Solution
A hybrid architecture is proposed where power electronics are both internal and external to the casing, with n power electronic modules distributed along the casing's internal circumference and a single annular DC bus capacitor, utilizing a cooling circuit with U-shaped tubes to enhance cooling and temperature resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If power electronics are integrated internally in the housing, then compactness is improved, but thermal constraints and volume of DC bus capacitors worsen
Solution Approach 1:
The power electronics are segmented into multiple modules distributed along the internal circumference of the housing extension, allowing thermal management to be distributed as well. The cooling circuit is segmented into multiple U-shaped tubes that can be strategically positioned to cool different modules, resolving the thermal constraints while maintaining compact integration.
Solution Approach 2:
The patent extends the housing in the longitudinal dimension to create space for power electronics modules and DC bus capacitors, moving them from a confined radial space to a distributed longitudinal arrangement. This dimensional change allows better thermal access while maintaining overall compactness.
2Power
If a large volume DC bus capacitor is used, then electrical performance is improved, but system volume and weight increase
Solution Approach 1:
The DC bus capacitors are nested within the housing extension, utilizing the extended longitudinal space rather than occupying additional external volume. The capacitors are positioned in the annular space between the housing wall and the power electronics modules, effectively nesting them within the existing structure.
Solution Approach 2:
Instead of using large radial capacitors that would increase volume, the patent distributes multiple smaller capacitors along the longitudinal extension, changing from a single large component to multiple distributed components in the longitudinal dimension.
3Ease of manufacture
If power electronics are radially integrated on the housing surface, then integration is simplified, but compactness and semiconductor device distribution worsen
Solution Approach 1:
The power electronics are segmented into multiple modules distributed along the internal circumference of the housing extension, improving both compactness and thermal management while maintaining integration simplicity through modular construction.
4Volume of moving object
If axial surface integration is used, then space requirements are reduced, but availability of end space worsens
Solution Approach 1:
The patent integrates power electronics along the internal circumference of a longitudinal extension rather than at the ends, utilizing the lateral surface area of the extended housing. This changes the integration from end-space-dependent to surface-area-dependent, improving adaptability while maintaining space efficiency.
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 power density, improves heat extraction, and enhances temperature resistance, addressing the limitations of previous integration methods while minimizing volume and weight.
Implementation Method 1
a cooling circuit with U-shaped tubes to enhance cooling and temperature resistance
Implementation Method 2
a cooling fluid 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
Data Source
Figure 1
Figure 2~5
Figure 3
AI summary
The invention relates to a polyphased electrical machine with n phases, n>3, comprising a housing (24) defining a longitudinal axis, a stator (26), and a rotor (28) comprising a mechanical drive shaft (30), the electrical machine being provided with power electronics (32) and a coolant circuit, said power electronics (32) being formed from n power electronics modules (32A1-32A6) which are regularly distributed over an inner circumference of a longitudinal extension (24A) of said housing, an outer circumference of which is covered by a single annular DC bus decoupling capacitor (16) which is electrically connected to said n power electronics modules (32A1-32A6), said coolant circuit comprising a plurality of U-shaped tubes with a tubular outgoing part (38A) extending over an entire length of the housing (24), including said longitudinal extension (24A) of the housing, and a shorter tubular return part (38B) extending over a length of the housing (24), excluding said longitudinal extension (24A) of the housing .