Segmented Rotor Input Shaft With Overrunning Clutches for Motor Redundancy
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Solution Overview
Problem
Aircraft propulsion systems with a single electric motor are prone to catastrophic failures and inefficient in meeting power demands, while dual motor systems introduce new complexities.
Innovation Solution
A segmented input shaft with integrated overrunning clutches connects multiple motors to a gearbox, allowing each motor to drive a segment of the shaft, enabling better quality control and reducing manufacturing challenges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single electric motor is used in the propulsion system, then the device complexity is reduced, but the reliability deteriorates due to lack of backup motor and increased likelihood of catastrophic failure
Solution Approach 1:
The propulsion system is segmented into multiple independent motor units, each capable of independent operation. The drive shaft is divided into multiple segments that can be independently driven by different motors, allowing the system to maintain functionality even if one motor fails.
Solution Approach 2:
Each segment of the drive shaft has localized driving capability through integrated overrunning clutches and motor connections, allowing different parts of the system to have different functional qualities - some segments can be driven while others are coasting, providing redundancy and flexibility.
2Device complexity
If a single electric motor is used, then the device complexity is reduced, but the power demand efficiency deteriorates due to inability to meet peak power requirements
Solution Approach 1:
The power delivery system is segmented into multiple motor units that can independently contribute to the total power output, allowing the system to scale power delivery based on demand by activating appropriate numbers and combinations of motor units.
Solution Approach 2:
The motor configuration allows dynamic adjustment of power contribution from each motor unit based on instantaneous power demands, enabling the system to optimize power distribution and meet peak demands efficiently.
3Reliability
If dual or multiple motors are used, then the reliability is improved through backup capability, but the device complexity increases due to additional components and integration challenges
Solution Approach 1:
The drive shaft is segmented into modular sections that can be independently manufactured, tested, and assembled. Each segment integrates with its associated motor unit as a complete module, simplifying the overall assembly process and reducing integration complexity.
Solution Approach 2:
The motor and drive shaft segment are merged into integrated units where the motor directly drives its associated shaft segment. This merging reduces the number of separate components and connection points, thereby reducing overall system complexity despite having multiple motors.
4Device complexity
If a single long drive shaft is used, then the device complexity is reduced, but the manufacturing precision requirements increase due to challenges in manufacturing and assembling long shafts
Solution Approach 1:
The drive shaft is divided into multiple shorter segments that can be manufactured with standard precision capabilities and then assembled together. This segmentation eliminates the need for manufacturing extremely long shafts with high precision, reducing both manufacturing difficulty and precision requirements.
Solution Approach 2:
Each drive shaft segment is pre-assembled and pre-tested as a complete unit with its associated motor and clutch components before final integration into the propulsion system. This preliminary assembly allows for quality control and precision verification at a manageable scale.
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 enhances reliability by providing a backup motor and improves power distribution efficiency, reducing manufacturing costs and precision requirements.
Implementation Method 1
each one of the drive shaft segments is driven by a different one of the motors connected to the drive shaft segment via an integrated overrunning clutch
Data Source
AI summary
A motor assembly is described and includes a housing; a plurality of motors disposed within the housing; and a drive shaft comprising a plurality of interconnected drive shaft segments, wherein each one of the drive shaft segments is driven by a different one of the motors connected to the drive shaft segment via an integrated overrunning clutch.