Rotary electric engines, aircraft including the same, and associated methods

Patent metadata

Field	Value
Publication number	US-11203439-B2
Application number	US-201916657822-A
Country	US
Kind code	B2
Filing date	Oct 18, 2019
Priority date	Oct 18, 2019
Publication date	Dec 21, 2021
Grant date	Dec 21, 2021

Abstract

Rotary electric engines, aircraft including the same, and associated methods. A rotary electric engine includes a nacelle, a fan configured to generate thrust, a stator operatively coupled to the nacelle, and a rotor operatively coupled to the fan. The fan includes a plurality of fan blades. The rotor includes a plurality of rotor magnets operatively coupled to respective blade tips of the fan blades. The stator includes a plurality of field coils configured to produce a magnetic interaction between the field coils and the rotor magnets to rotate the fan. In examples, the stator is configured to rotate each field coil relative to the nacelle. In examples, an aircraft includes one or more rotary electric engines pivotally mounted within engine mount regions. In examples, a method of operating an aircraft includes operating one or more rotary electric engines in a vertical lift configuration and in a forward flight configuration.

First claim

The invention claimed is:

1. A rotary electric engine for providing thrust to an aircraft via a rim-driven fan, the rotary electric engine comprising:
a fan configured to rotate about an electric engine central axis of the rotary electric engine to generate the thrust along an electric engine thrust direction;
a nacelle that at least substantially encompasses the fan;
a stator operatively coupled to the nacelle; and
a rotor operatively coupled to the fan;
wherein the fan includes a central hub and a plurality of fan blades extending from the central hub; wherein the plurality of fan blades extend at least substantially within a fan plane; wherein each fan blade of the plurality of fan blades includes a blade root that is operatively coupled to the central hub and a blade tip opposite the blade root; wherein the rotor includes a plurality of rotor magnets, each rotor magnet operatively coupled to a respective blade tip of a respective fan blade of the plurality of fan blades; wherein the stator includes a plurality of field coils; wherein the stator is configured such that, during operative use of the rotary electric engine, magnetic interaction between the plurality of field coils and the plurality of rotor magnets operates to rotate the fan about the electric engine central axis and to generate the thrust; and wherein the stator is configured to selectively and dynamically rotate each field coil of the plurality of field coils relative to the nacelle.

2. The rotary electric engine of claim 1 , wherein each fan blade of the plurality of fan blades is configured to rotate relative to the central hub and about a respective blade pitch axis of the fan blade; and wherein the stator is configured to selectively and dynamically rotate each field coil of the plurality of field coils to maintain each field coil in an orientation that is at least substantially aligned with each rotor magnet of the plurality of rotor magnets when each rotor magnet is proximate to the field coil and as each fan blade of the plurality of fan blades rotates about the respective blade pitch axis.

3. The rotary electric engine of claim 1 , wherein each field coil of the plurality of field coils has a coil first end, a coil second end opposite the coil first end, and a coil orientation axis that extends between the coil first end and the coil second end; wherein each field coil has a coil pitch angle, as measured between the coil orientation axis and the fan plane; and wherein each field coil of the plurality of field coils is configured to rotate relative to the nacelle about a respective coil pitch axis that extends perpendicular to the coil orientation axis to adjust the coil pitch angle.

4. The rotary electric engine of claim 3 , wherein the stator further includes a first support ring and a second support ring; wherein each field coil of the plurality of field coils is pivotally coupled to each of the first support ring and the second support ring; and wherein the stator is configured to selectively and dynamically rotate one or both of the first support ring and the second support ring about the electric engine central axis and relative to the nacelle to selectively and dynamically rotate each field coil of the plurality of field coils about the respective coil pitch axis.

5. The rotary electric engine of claim 1 , wherein each fan blade has a blade longitudinal axis that extends from the blade root to the blade tip; wherein each rotor magnet of the plurality of rotor magnets has a magnet shape, as viewed along the blade longitudinal axis of the corresponding fan blade of the plurality of fan blades, that has at least one magnet shape edge that is at least partially curved; and wherein each field coil of the plurality of field coils has a coil shape, as viewed along the blade longitudinal axis of a corresponding fan blade of the plurality of fan blades when the field coil is aligned with the corresponding fan blade, that at least substantially matches the magnet shape of each rotor magnet.

6. The rotary electric engine of claim 1 , wherein each field coil of the plurality of field coils includes a coil core and a coil wire wrapped around the coil core.

7. The rotary electric engine of claim 6 , further comprising an electric power system configured to provide an electric power input to the stator, wherein the electric power input includes an electric current that is supplied to the respective coil wire of each field coil of the plurality of field coils, and wherein the electric power input is configured to coordinate the electric current that is supplied to the respective coil wire of each field coil of the plurality of field coils to rotate the fan at a selected fan rotational velocity.

8. The rotary electric engine of claim 7 , further comprising an electric generator that is configured to generate an electric power output, and wherein the electric power system includes an energy storage device configured to:
(i) provide the electric power input to the stator; and
(ii) receive and store the electric power output that is generated by the electric generator.

9. The rotary electric engine of claim 8 , wherein the electric generator includes the stator and the rotor.

10. The rotary electric engine of claim 1 , further comprising a nacelle heating structure for heating at least a portion of the nacelle during operative use of the rotary electric engine; wherein the nacelle heating structure is configured to inhibit a formation of ice upon the nacelle during operative use of the rotary electric engine; and wherein the nacelle heating structure includes a thermal coupling structure configured to enhance thermal communication between at least a portion of the stator and at least a portion of the nacelle to convey heat energy from the stator to the nacelle.

11. The rotary electric engine of claim 10 , wherein the nacelle includes a lip skin that at least partially defines an air intake of the rotary electric engine, and wherein the thermal coupling structure is configured to convey heat energy from the stator to the lip skin.

12. An aircraft, comprising:
a fuselage;
one or more wings operatively coupled to the fuselage;
one or more instances of the rotary electric engine of claim 1 ; and
one or more engine mount regions, each engine mount region operatively supporting a respective instance of the rotary electric engine therein;
wherein each wing includes one or more of the engine mount regions; and wherein each rotary electric engine supported within each engine mount region of each wing is a wing rotary electric engine.

13. The aircraft of claim 12 , wherein each rotary electric engine is configured to selectively transition between a plurality of configurations defined between and including two or more of:
(i) a vertical lift configuration, in which the respective electric engine thrust direction of the rotary electric engine is directed at least substantially vertically upward relative to the aircraft;
(ii) a forward flight configuration, in which the respective electric engine thrust direction of the rotary electric engine is directed at least substantially in a forward direction of the aircraft;
(iii) a reverse flight configuration, in which the respective electric engine thrust direction of the rotary electric engine is directed at least substantially in an aft direction of the aircraft; and
(iv) a lift counterforce configuration, in which the respective electric engine thrust direction of the rotary electric engine is directed at least substantially vertically downward relative to the aircraft.

14. The aircraft of claim 13 , wherein each rotary electric engi

Assignees

• Boeing Co

Inventors

• Berkey Tyler Emerson
• Thomas Daniel S

Classifications

• B64D27/35

  Arrangements for on-board electric energy production, distribution, recovery or storage · CPC title

• B64D27/34

  All-electric aircraft · CPC title

• B64C11/001 Primary

  Shrouded propellers · CPC title

• B64D35/00

  Transmitting power from power plants to propellers or rotors; Arrangements of transmissions · CPC title

• B64C39/12

  Canard-type aircraft · CPC title