ELECTRIC AIRCRAFT PROPULSION ASSEMBLY AND METHOD
20230278721 · 2023-09-07
Assignee
Inventors
- David R TRAINER (Derby, GB)
- Francisco Javier CHIVITE ZABALZA (Stafford, GB)
- Ellis F H CHONG (Derby, GB)
Cpc classification
B64D2221/00
PERFORMING OPERATIONS; TRANSPORTING
B60L2220/42
PERFORMING OPERATIONS; TRANSPORTING
B64D35/02
PERFORMING OPERATIONS; TRANSPORTING
Y02T50/60
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B60L50/60
PERFORMING OPERATIONS; TRANSPORTING
B64D35/00
PERFORMING OPERATIONS; TRANSPORTING
B64C29/0016
PERFORMING OPERATIONS; TRANSPORTING
B64D35/04
PERFORMING OPERATIONS; TRANSPORTING
International classification
B64D35/00
PERFORMING OPERATIONS; TRANSPORTING
B64C29/00
PERFORMING OPERATIONS; TRANSPORTING
B60L50/60
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The disclosure relates to an electric aircraft propulsion assembly for an electric vertical takeoff and landing, eVTOL, aircraft, the assembly comprising: an electric storage unit; a first electric motor connected to power a first propulsor; a first converter configured as a DC:AC converter for driving the first electric motor and a second electric motor connected to power a second propulsor, a second converter. A controller is connected to control operation of the first and second converters and is configured to operate in a first mode in which the first and second converters are operated as DC:AC converters to drive the first and second electric motors and a second mode in which the first converter is operated to drive the first electric motor to power the first propulsor and the second converter is operated to drive the second electric motor to provide a braking torque on the second propulsor.
Claims
1. An electric aircraft propulsion assembly for an electric vertical takeoff and landing (eVTOL) aircraft, the assembly comprising: an electric storage unit; a first electric motor connected to power a first propulsor; a first converter configured as a DC:AC converter having input connections connectable to the electric storage unit and output connections connected to the first electric motor, the first converter configured to convert a DC supply across the input connections to an AC supply across the output connections; a second electric motor connected to power a second propulsor; a second converter connected between the first converter input connections and the second electric motor; and a controller connected to control operation of the first and second converters, wherein the controller is configured to operate in a first mode in which the first and second converters are operated as DC:AC converters to drive the first and second electric motors and a second mode in which the first converter is operated to drive the first electric motor to power the first propulsor and the second converter is operated to drive the second electric motor to provide a braking torque on the second propulsor.
2. The electric aircraft propulsion assembly of claim 1, wherein the second electric motor comprises a plurality of windings and the second converter comprises a respective plurality of switching circuits, the controller in the second mode being configured to drive first and second ones of the switching circuits to provide an AC current through respective first and second windings of the second electric motor to provide the braking torque on the second propulsor.
3. The electric aircraft propulsion assembly of claim 2, wherein the controller is configured in the second mode to control the AC current to maintain the second propulsor stationary.
4. The electric aircraft propulsion assembly of claim 3, wherein the controller is configured to control the AC current to rotate the propulsor to a preset position prior to maintaining the propulsor stationary.
5. The electric aircraft propulsion assembly of claim 1, wherein in the second mode, the second converter is configured as a DC:DC converter to convert the DC supply from the electric storage unit at a first DC voltage level to a DC supply at a second DC voltage level.
6. The electric aircraft propulsion assembly of claim 1, wherein the second electric motor comprises a plurality of windings and the controller is configured in the second mode to operate the second converter to drive differential currents through the plurality of windings to provide a torque on the second propulsor.
7. The electric aircraft propulsion assembly of claim 6, further comprising a rotation sensor connected to the second propulsor, wherein the controller is configured in the second mode to receive a rotation signal from the rotation sensor and to control the differential currents to reduce or minimise the rotation signal.
8. The electric aircraft propulsion assembly of claim 6, wherein the controller is configured in the second mode to control the differential currents to maintain a constant sum of currents through the plurality of windings.
9. The electric aircraft propulsion assembly of claim 5, wherein the second electric motor comprises a plurality of windings and the second converter comprises a respective plurality of switching circuits and first and second input terminals, the assembly further comprising a switching arrangement that, in a first configuration, connects a first terminal of the electric storage unit to the first input terminal of the second converter and, in a second configuration, connects the first terminal of the electric storage unit to a node common to the plurality of windings, a second terminal of the electric storage unit remaining connected to the second input terminal, the controller being configured in the second mode to operate the switching arrangement in the second configuration and operate the plurality of switching circuits as a DC:DC converter to convert the first DC voltage level across the terminals of the electric storage unit to the second DC voltage level across the first and second terminals of the second converter.
10. The electric aircraft propulsion assembly of claim 5, wherein the second DC voltage level is higher than the first DC voltage level.
11. The electric aircraft propulsion assembly of claim 9, wherein each of the plurality of switching circuits comprises: a pair of switches, a node between the pair of switches being connected to a respective one of the plurality of windings; or an H-bridge converter connected to a respective one of the plurality of windings.
12. An electric vertical takeoff and landing (eVTOL) aircraft comprising an electric aircraft propulsion assembly according to claim 1.
13. A method of operating an electric vertical takeoff and landing (eVTOL) aircraft comprising an electric aircraft propulsion assembly comprising: an electric storage unit; a first electric motor connected to power a first propulsor; a first converter configured as a DC:AC converter having input connections connectable to the electric storage unit and output connections connected to the first electric motor, the first converter configured to convert a DC supply across the input connections to an AC supply across the output connections; a second electric motor connected to power a second propulsor; a second converter connected between the first converter input connections and the second electric motor; and a controller connected to control operation of the first and second converters, the method comprising: operating the controller in a first mode in which the first and second converters are operated as DC:AC converters to drive the first and second electric motors; and operating the controller in a second mode in which the first converter is operated to drive the first electric motor to power the first propulsor and the second converter is operated to drive the second electric motor to provide a braking torque on the second propulsor.
14. The method of claim 13, wherein the second electric motor comprises a plurality of windings and the second converter comprises a respective plurality of switching circuits, the controller in the second mode driving first and second ones of the switching circuits to provide an AC current through respective first and second windings of the second electric motor to provide the braking torque on the second propulsor.
15. The method of claim 14, wherein the controller in the second mode controls the AC current to maintain the propulsor stationary.
16. The method of claim 15, wherein the controller controls the AC current to rotate the propulsor to a preset position prior to maintaining the propulsor stationary.
17. The method of claim 13, wherein in the second mode, the second converter is configured as a DC:DC converter to convert the DC supply from the electric storage unit at a first DC voltage level to a DC supply at a second DC voltage level.
18. The method of claim 13, wherein the second electric motor comprises a plurality of windings and the controller in the second mode operates the second converter to drive differential currents through the plurality of windings to provide a torque on the second propulsor.
19. The method of claim 18, wherein the controller in the second mode controls the differential currents to maintain a constant sum of currents through the plurality of windings.
20. The method of claim 18, wherein a rotation sensor is connected to the second propulsor, the controller in the second mode receiving a rotation signal from the rotation sensor and controlling the differential currents to reduce or minimise the rotation signal.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] Embodiments will now be described by way of example only with reference to the accompanying drawings, which are purely schematic and not to scale, and in which:
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DETAILED DESCRIPTION
[0066]
[0067] In this arrangement, the battery 202a-d provides power to both sets of DC:AC converters 207a-d. 208a-d. The voltage provided by the battery 202a-d reduces as the battery discharges its stored energy during flight, requiring more current to be provided for the same power, resulting in higher losses.
[0068] The system 200 in
[0069] For prolonged periods during flight, some of the converters and motors will be non-operational, for example the rear converters 208a-d and motors 204a-d. The corresponding propulsors 206a-d may be locked in position during cruise flight while the forward motors 203a-d drive the forward propulsors 205a-d. The second converters 208a-d may therefore, in some embodiments described herein, be re-utilised if configured to operate during cruise flight as DC:DC converters instead.
[0070]
[0071] First and second converters 307, 308 convert the DC supply from the battery 302 to an AC supply for the respective first and second electric motors 303, 304. Each converter 307, 308 is operated by a controller 310, which provides switching signals to the converters 307, 308 for controlling the AC supply provided to each motor 303, 304, controlling the level of power provided to each motor 303, 304. The controller 310 is configured to operate in a first mode in which the first and second converters 307, 308 are operated to drive the respective first and second electric motor 303, 304, which may be used during takeoff and landing of the aircraft, where each propulsor 305, 306 is providing vertical thrust. The controller 310 is also configured to operate in a second mode in which the first converter 303 is operated to drive the first electric motor 303 while the second converter 306 is operated to drive the second electric motor 304 to provide a braking torque on the second propulsor. This second mode may be used during forward flight conditions, where the first propulsor 305 is providing forward thrust and the second propulsor is fixed. Aerodynamic forces may tend to rotate the second propulsor during forward flight, which can be counteracted by the braking torque on the second propulsor 306 provided by the second electric motor 304.
[0072] The second converter 308 may be operated in the second mode in two configurations to achieve the same aim. In a first configuration, the second converter is operated as a DC:AC converter to inject current into phases of the second motor 304 to generate a torque to oppose any aerodynamic torque applied to the propulsor 306. This configuration may for example be used when the battery 302 is at a higher state of charge. In a second configuration, the second converter 308 may be operated as a DC:DC converter, using the phases of the electric motor as an inductor in a boost converter. This configuration may be used for any battery state of charge, but may be more applicable when the supply voltage across the battery 302 has reduced such that a DC boost is required, which is supplied to the first converter 307.
[0073]
[0074] In the first mode, the controller 310 controls the switching circuits 402a-c to provide an AC supply to the electric motor 304 for powering the propulsor 306. A similar arrangement may be provided for the first electric motor 303 and first propulsor 305.
[0075] In the second mode, where the propulsor 306 is not driven to provide thrust, aerodynamic forces 403 acting on the propulsor 306 will tend to drive the propulsor 306 unless a brake is applied to the shaft 404 linking the propulsor to the motor 304. A mechanical brake may be used for this purpose, which locks the propulsor 306 in a set position when the electric motor 304 is not being driven. In this arrangement, however, a brake is applied to the propulsor 306 by driving the motor 304 to either replace or supplement a mechanical brake. In this mode of operation, the converter 308 is operated as a DC:AC converter to inject current into the motor 304 to generate a torque to oppose the aerodynamic forces 403. This may be achieved by driving current 405 through a pair of windings of the motor 304. In the illustrated example, this is achieved by operating the first and second switching circuits 402a, 402b to drive an AC current 405 through the first and second windings 406a, 406b of the motor 304. The AC current 405 is controlled to be sufficient to counteract the torque generated by aerodynamic loading 403 acting on the propulsor 306. The motor shaft 404 and propulsor 306 may be held stationary using only the torque provided by the motor 304. Before the propulsor 306 is held stationary it may first be moved to a preset position, for example to maximise interaction with the magnetic field generated by the windings 406a, 406b so that the current 405 flowing through the windings 406a, 406b can be minimised during braking.
[0076]
[0077] A mechanical lock 504 may be provided to hold the shaft 404 connecting the electric motor 304 to the propulsor (not shown in
[0078] With the switch 501 in the first position, the controller 310 operates to drive the converter 308 as a DC:AC converter, driving AC current through the electric motor 304 to drive the propulsor, for example during vertical takeoff and landing mode of the aircraft.
[0079] With the switch 501 in the second position, the converter 308 can be reconfigured to operate as a DC:DC converter using one or more of the switching circuits 402a-c in combination with an inductance between the first terminal 302+ of the battery 302 and each pair of switching circuits 402a-c. In the example shown in
[0080] A boost converter may be provided using one or more of the switching circuits. If more than one switching circuit is used, the switching circuits 402a-c may be operated by the controller 310 such that switching of each pair is interleaved so as to reduce fluctuations in the DC output supply provided across the terminals 502a, 502b.
[0081] When the supply voltage across the battery 302 is reduced due to the battery 302 having been partially discharged, the DC boost converter provided by the converter 308 with the switch 501 in the second position can be used to raise the DC voltage supply to a nominal level for powering the first converter 307 and first motor 303 (
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[0084] The principle shown in
[0085] In the arrangement shown in
[0086] The currents do not need to be equal, but can be adjusted to provide the required imbalance to generate a torque while maintaining a stable output current for the first converter 307 and first electric motor 303 (
[0087] The configurations described above with reference to
[0088] The first DC:DC configuration is illustrated schematically in
[0089] In either of the first and second DC:DC configurations, the switching circuits of the converter 308 may be operated using interleaving as described above in relation to
[0090] To operate the converter as a DC:AC converter to drive the motor 304, the first and third switches 901, 903 are open and the second and fourth switches 902, 904 closed. The configuration is then equivalent to that illustrated in
[0091] The imbalance in the DC:DC converter current in each phase may be altered dynamically such that the current has an alternating component, as shown schematically in
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[0093] It should be appreciated that each assembly described herein is not limited to having only one first converter and second converter with associated motors and propulsors, but may have multiple first converters and/or multiple second converters and may have a different number of first converters to second converters depending on the required application. The assembly may for example have a higher number of second converters given that lift will require greater power input than forward cruise. Also, the number of motors driven by each converter may be more than one, and the number of phases of each motor may be other than three or four. A single electric storage unit may be connected to more than one assembly, allowing for power sharing between different assemblies to improve fault tolerance and reconfigurability.
[0094] Other embodiments not disclosed herein are also within the scope of the invention, which is defined by the appended claims.