Integrated Rectifier Housing for Heat, EMI, and Shock Loads
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Solution Overview
Problem
Hybrid electric propulsion systems face challenges in managing high-density heat loads, shock loads from high-G maneuvers or hard landings, and electromagnetic interference, particularly in converting alternating current to direct current and back for efficient power distribution in aircraft propulsion systems.
Innovation Solution
The integration of a housing for power electronics within the propulsion system using ultrasonic additive manufacturing, which incorporates thermal management features, electromagnetic interference shielding, and shock load reinforcement, including a composite material base with ceramic fibers and a heat shield, along with embedded sensors for temperature and strain measurement, to protect electrical components and enhance cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate components are used for thermal management, electromagnetic shielding, and shock reinforcement, then each function can be optimized independently, but the overall device complexity and weight increase
Solution Approach 1:
The patent combines thermal management features, electromagnetic interference shielding, and shock load reinforcement into a single integrated housing structure. The housing includes integrated cooling passageways, electromagnetic shielding layers, and shock-absorbing features all as one unified component rather than separate attachments, thereby reducing overall system complexity while maintaining comprehensive protection of electrical components
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical protection, thermal management through integrated cooling passageways, electromagnetic shielding through conductive layers, and shock absorption through compliant features. This multi-functionality eliminates the need for separate components for each protective function
2Ease of manufacture
If traditional manufacturing methods are used for the housing, then assembly is simpler, but integration of thermal management and shielding features becomes more complex
Solution Approach 1:
The housing is designed as an integrated structure where cooling passageways, electromagnetic shielding layers, and structural elements are combined into a single manufactured component. This integration is achieved through ultrasonic additive manufacturing, which allows complex internal features to be built directly into the housing during the manufacturing process rather than requiring post-assembly integration
3Device complexity
If ultrasonic additive manufacturing is used to integrate thermal management and shielding features, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The ultrasonic additive manufacturing process utilizes controlled parameter changes including ultrasonic frequency, amplitude, and tool path parameters to achieve precise material deposition and bonding. These parameter controls enable the manufacturing of complex integrated housing features with required dimensional accuracy and material properties
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 solution effectively manages heat loads, withstands shock and electromagnetic interference, and reduces weight by integrating cooling passageways and shielding within the housing, ensuring reliable and efficient power conversion and distribution for aircraft propulsion systems.
Implementation Method 1
The base may be formed to include a cooling passageway. The cooling passageway may extend therethrough to transfer a flow of cooling fluid through the base to cool the electrical components mounted to the base.
Implementation Method 2
The heat shield may comprise a third metallic material having thermal resistance greater than the first metallic material. The heat shield may extend around an outer surface of the base plate to protect the base plate from high temperatures.
Implementation Method 3
The heat transfer pedestal may include a plate and a plurality of fins. The plate may be flush with an inner surface of the base plate to close an opening to the cavity. The plurality of fins may extend from the plate into the cavity so as to be in fluid communication with the cooling fluid.
Implementation Method 4
The vibration dampers may extend between and interconnect the base to the aircraft to minimize the vibrations transferred to the base and the cover.
Data Source
AI summary
A propulsion system for use with an aircraft includes a gas turbine engine, an electric power system, and at least one propulsor. The gas turbine engine includes a compressor, a combustor, and a turbine. The electric power system includes a generator coupled to the gas turbine engine to generate electrical energy, power electronics connected to the generator to receive the electrical energy from the generator, and a motor configured to produce rotational energy in response to receiving electric energy from the power electronics. The propulsor is configured to use rotational energy received from the motor of the electric power system to generate thrust for propelling the aircraft.