Aircraft electric propulsion system with overlapping shafts for gearbox oil distribution

Patent metadata

Field	Value
Publication number	US-12286234-B2
Application number	US-202418620505-A
Country	US
Kind code	B2
Filing date	Mar 28, 2024
Priority date	Oct 6, 2022
Publication date	Apr 29, 2025
Grant date	Apr 29, 2025

Abstract

An electric propulsion system for a vertical take-off and landing (VTOL) aircraft having a heat exchanger to cool fluids used in an electrical engine, the electric propulsion system comprising at least one electrical engine mechanically connected directly or indirectly to a fuselage of the VTOL aircraft and electrically connected to an electrical power source. The electrical engine may comprise an electrical motor having a stator and a rotor; a gearbox assembly comprising a sun gear; at least one planetary gear; a ring gear; and a planetary carrier. The electric engine may include an inverter assembly comprising a thermal plate and an inverter assembly housing; an end bell assembly that is connected to the thermal plate of the inverter assembly; and a heat exchanger comprising an array of cooling fins and tubes.

First claim

What is claimed is:

1. An electric propulsion system for an aircraft, the electric propulsion system comprising:
at least one electrical engine configured to be mechanically connected directly or indirectly to a fuselage of the aircraft and electrically connected to an electrical power source, wherein the electrical engine comprises:
an electric motor comprising a stator and a rotor;
a main shaft having a first end and a second end;
a secondary shaft surrounding the main shaft and substantially overlapping the main shaft, wherein the secondary shaft comprises an inner surface that is tapered; and
an inverter assembly that provides alternating current to the electric motor; and

a propeller assembly connected to the second end of the main shaft,
wherein the main shaft extends away from the inverter assembly to the second end of the main shaft, wherein a rotation of the main shaft is configured to distribute a fluid through the secondary shaft.

2. The system of claim 1 , wherein the fluid includes oil.

3. The system of claim 1 , wherein the fluid is used to cool the electrical engine.

4. The system of claim 1 , wherein the fluid is used to lubricate the electrical engine.

5. The system of claim 1 , wherein the secondary shaft comprises:
a first secondary shaft end located above the main shaft when oriented in a cruise configuration of the electric propulsion system; and
a second secondary shaft end located proximate to the propeller assembly.

6. The system of claim 5 , wherein an inner diameter of the first secondary shaft end is less than an inner diameter of the second secondary shaft end.

7. The system of claim 1 , wherein the electric motor, the inverter assembly, the propeller assembly, and the secondary shaft are concentrically aligned with the main shaft.

8. An electric propulsion system for a vertical take-off and landing (VTOL) aircraft, the electric propulsion system comprising:
at least one electrical engine configured to be mechanically connected directly or indirectly to a fuselage of the VTOL aircraft and electrically connected to an electrical power source, wherein the electrical engine comprises:
an electric motor comprising a stator and a rotor; and
a main shaft having a first end and a second end;
a secondary shaft surrounding the main shaft and substantially overlapping the main shaft, wherein the secondary shaft comprises an inner surface that is tapered; and

a propeller assembly connected to the second end of the main shaft, wherein a rotation of the main shaft is configured to distribute a fluid through the secondary shaft.

9. The system of claim 8 , wherein the fluid includes oil.

10. The system of claim 8 , wherein the fluid is used to cool or lubricate the electrical engine.

11. The system of claim 8 , wherein the electric motor, the propeller assembly, and the secondary shaft are concentrically aligned with the main shaft.

12. A method of operating an electric propulsion system for a vertical take-off and landing (VTOL) aircraft, the method comprising:
rotating a propeller of a propeller assembly by an electrical engine of the VTOL aircraft, wherein the electrical engine comprises:
an electric motor comprising a stator and a rotor;
a main shaft having a first end and a second end;
a secondary shaft surrounding the main shaft and substantially overlapping the main shaft, wherein the secondary shaft comprises an inner surface that is tapered; and
an inverter assembly that provides alternating current to the electric motor;

wherein the propeller assembly is connected to the second end of the main shaft,
wherein the main shaft extends away from the inverter assembly to the second end of the main shaft, and
distributing a fluid through the secondary shaft by a rotation of the main shaft.

13. The method of claim 12 , wherein the fluid includes oil.

14. The method of claim 12 , wherein the fluid is used to cool the electrical engine.

15. The method of claim 12 , wherein the fluid is used to lubricate the electrical engine.

16. The method of claim 12 , wherein the secondary shaft comprises:
a first secondary shaft end located above the main shaft when oriented in a cruise configuration of the electric propulsion system; and
a second secondary shaft end located proximate to the propeller assembly.

17. The method of claim 16 , wherein an inner diameter of the first secondary shaft end is less than an inner diameter of the second secondary shaft end.

18. The method of claim 12 , wherein the electric motor, the inverter assembly, the propeller assembly, and the secondary shaft are concentrically aligned with the main shaft.

19. The system of claim 1 , wherein the tapered inner surface of the secondary shaft substantially overlaps a non-tapered surface of the main shaft.

Assignees

• Archer Aviation Inc

Inventors

• Graves Scott
• Tepe Alan D

Classifications

• H02K15/40

  Assembling dynamo-electric machines (H02K15/16 takes precedence) · CPC title

• H02K15/035

  on the rotor · CPC title

• H02K2215/00

  Specific aspects not provided for in other groups of this subclass relating to methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines · CPC title

• H02P27/08

  with pulse width modulation · CPC title

• H02P27/06

  using DC to AC converters or inverters (H02P27/05 takes precedence) · CPC title