Aircraft propulsion system including pump gear driven by planetary gearbox assembly

Patent metadata

Field	Value
Publication number	US-12473074-B2
Application number	US-202519016983-A
Country	US
Kind code	B2
Filing date	Jan 10, 2025
Priority date	Oct 6, 2022
Publication date	Nov 18, 2025
Grant date	Nov 18, 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 . A propulsion system for an aircraft, the propulsion system comprising:
a main shaft; a gearbox assembly configured to drive the main shaft, the gearbox assembly comprising:
at least one planetary gear;
a planetary carrier;
a cover;
a pump drive gear attached to at least one of the planetary carrier or the cover, wherein the pump drive gear is concentrically aligned with the main shaft; and
a pump gear configured to interface rotor that interfaces with the pump drive gear.

2 . The system of claim 1 , further comprising a fluid reservoir and a heat exchanger, wherein the pump drive gear is configured to drive the pump gear to transfer a fluid from the fluid reservoir to the heat exchanger through a fluid inlet in the fluid reservoir.

3 . The system of claim 1 , wherein the cover is coupled to the main shaft.

4 . The system of claim 3 , wherein the pump drive gear is positioned between the planetary carrier and the cover.

5 . The system of claim 1 , wherein the at least one planetary gear comprises a compound planetary gear, wherein the compound planetary gear comprises at least two planetary gears concentrically aligned on a shared shaft.

6 . The system of claim 5 , wherein the pump drive gear is positioned between the at least two planetary gears of the compound planetary gear.

7 . The system of claim 1 , wherein the pump gear is configured to pump a fluid from a fluid reservoir at a flow rate that is proportional to a speed of rotation of a propeller assembly, wherein the propeller assembly is mechanically coupled to the main shaft.

8 . The system of claim 1 , further comprising a housing at a first end of the main shaft, the housing comprising:
a plate; a first circular wall extending from the plate; and a second circular wall extending from the plate, wherein a diameter of the second circular wall is less than a diameter of the first circular wall.

9 . The system of claim 8 , further comprising a region defined by the first circular wall and the second circular wall, wherein the region defines a dry zone.

10 . The system of claim 9 , wherein the region is concentrically aligned with the main shaft.

11 . The system of claim 1 , wherein the pump drive gear is attached to the planetary carrier and the cover.

12 . A method of operating a propulsion system an aircraft, the method comprising:
operating a gearbox assembly to drive a main shaft comprising:
rotating at least one planetary gear, a cover, and a planetary carrier that supports the at least one planetary gear;
rotating a pump drive gear attached to at least one of the planetary carrier or the cover, wherein the pump drive gear is concentrically aligned with the main shaft; and
operating a pump gear through the rotation of the pump drive gear to transfer a fluid from a fluid reservoir.

13 . The method of claim 12 , further comprising driving the pump gear by the pump drive gear to transfer the fluid from the fluid reservoir to a heat exchanger through a fluid inlet in the fluid reservoir.

14 . The method of claim 12 , wherein the rotating the pump drive gear is performed by rotating at least one of the planetary carrier or the cover.

15 . The method of claim 12 , wherein the at least one planetary gear comprises a compound planetary gear comprising at least two planetary gears concentrically aligned on a shared shaft, and wherein rotating at least one planetary gear comprises rotating the compound gear.

16 . The method of claim 12 , further comprising, pumping, by the pump gear, the fluid from the fluid reservoir at a flow rate that is proportional to a speed of rotation of a propeller assembly, wherein the propeller assembly is mechanically coupled to the main shaft.

17 . The method of claim 16 , wherein the pump drive gear is attached to the planetary carrier and the cover and wherein the rotating the pump drive gear is performed by rotating the planetary carrier and the cover.

18 . The method of claim 12 , wherein rotating the pump drive gear is performed around an axis of the main shaft.

19 . An aircraft comprising:
a boom; a propulsion system coupled to the boom, the propulsion system comprising:
a main shaft;
a propeller assembly coupled to the main shaft;
a gearbox assembly configured to drive the main shaft, the gearbox assembly comprising:
at least one planetary gear;
a planetary carrier;
a cover; and
a pump drive gear attached to at least one of the planetary carrier or the cover, wherein the pump drive gear is concentrically aligned with the main shaft; and
a pump gear configured to interface with the pump drive gear.

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