Systems and methods for oil maintenance in gearboxes for eVTOL aircraft

Patent metadata

Field	Value
Publication number	US-12227300-B2
Application number	US-202418620917-A
Country	US
Kind code	B2
Filing date	Mar 28, 2024
Priority date	Oct 6, 2022
Publication date	Feb 18, 2025
Grant date	Feb 18, 2025

Abstract

An electric propulsion system comprising an electric motor assembly. The electric motor assembly may include a housing having an internal volume, a stator ring disposed about a perimeter of the internal volume, and a rotor positioned within the stator. The electric motor assembly may include a main shaft connected to the rotor via a gear reduction, wherein the main shaft extends through the rotor. The electric motor assembly may include a collar connected to the main shaft, wherein the collar encircles the main shaft, and at least a portion of the collar is configured to direct a fluid away from the main shaft and toward the stator ring.

First claim

What is claimed is:

1. A motor assembly for an electric propulsion system, the motor assembly comprising:
a motor housing;
a stator ring disposed about an interior perimeter of the motor housing;
a rotor positioned within the stator ring;
a main shaft connected to the rotor via a gear reduction, wherein the main shaft extends through the rotor;
a power inverter comprising:
an inverter housing mounted to a first end of the motor housing; and
circuitry configured to:
receive an input of a direct current;
convert the direct current to an alternating current; and
provide the alternating current to the stator ring of the motor assembly; and

a fluid distribution system comprising:
a fluid reservoir within the motor housing;
a pump configured to distribute a fluid to a component of the motor assembly; and
a filter configured to filter the fluid, wherein the filter is located adjacent to the main shaft at the first end of the motor housing, wherein the fluid distribution system is configured to direct the fluid from an outer circumferential side of the filter toward an inner side of the filter.

2. The motor assembly of claim 1 , wherein the filter is ring-shaped.

3. The motor assembly of claim 1 , wherein the inner side of the filter is located adjacent to a bearing of the main shaft.

4. The motor assembly of claim 1 , wherein the filter is configured to filter the fluid that lubricates at least a portion of the main shaft.

5. The motor assembly of claim 1 , wherein the pump is a sump pump.

6. The motor assembly of claim 1 , wherein the filter includes a filter media surrounding a ring-shaped support tube.

7. The motor assembly of claim 1 , wherein the filter is located between the power inverter and at least a portion of the motor assembly.

8. The motor assembly of claim 1 , wherein the electric propulsion system provides propulsion for an electric aircraft.

9. The motor assembly of claim 8 , wherein the electric aircraft is an electric vertical takeoff and landing (eVTOL) aircraft.

10. The motor assembly of claim 1 , wherein the fluid is distributed for at least one of cooling or lubricating parts of the electric motor assembly.

11. The motor assembly of claim 1 , wherein the fluid is oil.

12. A method of operating an electric propulsion system for an aircraft, the method comprising:
rotating a propeller by an electric motor assembly, the electric motor assembly comprising:
a motor housing;
a stator ring disposed about an interior perimeter of the motor housing;
a rotor positioned within the stator ring;
a main shaft connected to the rotor via a gear reduction, wherein the main shaft extends through the rotor;
a power inverter comprising:
an inverter housing mounted to a first end of the motor housing; and
circuitry configured to:
receive an input of a direct current;
convert the direct current to an alternating current; and
provide the alternating current to the stator ring of the electric motor assembly; and

a fluid distribution system comprising:
a fluid reservoir within the motor housing;
a pump; and
a filter located adjacent to the main shaft at the first end of the motor housing, wherein the fluid distribution system is configured to direct the fluid from an outer circumferential side of the filter toward an inner side of the filter;

distributing a fluid to a component of the motor assembly; and
filtering the fluid with the filter.

13. The method of claim 12 , wherein the filter is ring-shaped.

14. The method of claim 12 , wherein the inner side of the filter is located adjacent to a bearing of the main shaft.

15. The method of claim 12 , wherein the filter is configured to filter the fluid that lubricates at least a portion of the main shaft.

16. The method of claim 12 , wherein the pump is a sump pump.

17. The method of claim 12 , wherein the filter includes a filter media surrounding a ring-shaped support tube.

18. The method of claim 12 , wherein the filter is located between the power inverter and at least a portion of the electric motor assembly.

19. The method of claim 12 , wherein the fluid is distributed for at least one of cooling or lubricating parts of the electric motor assembly.

20. The method of claim 12 , wherein the fluid is oil.

21. The motor assembly of claim 1 , wherein directing the fluid from an outer circumferential side of the filter toward an inner side of the filter comprises directing the fluid radially inward towards the main shaft.

22. The motor assembly of claim 1 , wherein the filter is coupled to the main shaft.

23. The motor assembly of claim 21 , wherein a circumference of the inner side of the filter contacts the main shaft.

Assignees

• Archer Aviation Inc

Inventors

• Graves Scott
• Moore Robert Wayne

Classifications

• F16H57/0417

  Heat exchangers adapted or integrated in the gearing · CPC title

• F16H57/0416

  Air cooling or ventilation · CPC title

• F16H57/0476

  Electric machines and gearing, i.e. joint lubrication or cooling or heating thereof · CPC title

• F16H57/082

  Planet carriers · CPC title

• B64D27/34

  All-electric aircraft · CPC title