Systems and methods for oil management in gearboxes for EVTOL aircraft

Patent metadata

Field	Value
Publication number	US-12486022-B2
Application number	US-202418989418-A
Country	US
Kind code	B2
Filing date	Dec 20, 2024
Priority date	Oct 6, 2022
Publication date	Dec 2, 2025
Grant date	Dec 2, 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:
an electric motor comprising a stator and a rotor; a main shaft; a propeller assembly coupled to the main shaft; a motor housing comprising a sump, wherein the main shaft and electric motor are located in the motor housing; an end bell assembly connected to the motor housing, the end bell assembly comprising:
a plate; and
a fluid inlet extending into the sump, wherein the fluid inlet is configured to distribute fluid through the end bell assembly.

2 . The system of claim 1 , wherein the sump is configured to store the fluid for cooling the propulsion system.

3 . The system of claim 1 , wherein the sump is configured to store the fluid for lubricating the propulsion system.

4 . The system of claim 1 , wherein the fluid comprises oil for cooling and lubricating the propulsion system.

5 . The system of claim 1 , wherein the sump is configured to store an amount of oil that is not more than three quarts.

6 . The system of claim 1 , wherein the sump includes the fluid, wherein the fluid travels from the sump, through the fluid inlet, to the plate and to a heat exchanger.

7 . The system of claim 1 , further comprising a tilting mechanism configured to change an orientation of the propulsion system.

8 . The system of claim 7 , wherein the fluid inlet is positioned within the sump such that the fluid inlet remains in contact with the fluid in the sump when the tilting mechanism changes the orientation of the propulsion system.

9 . The system of claim 1 , wherein the motor housing is connected to the plate of the end bell assembly.

10 . The system of claim 1 , further comprising an inverter assembly, wherein the electric motor, the end bell assembly, and the inverter assembly are concentrically aligned with the main shaft.

11 . The system of claim 1 , further comprising an inverter assembly, wherein the motor housing is positioned between the inverter assembly and the propeller assembly.

12 . The system of claim 11 , wherein the propeller assembly is configured to direct an air flow past the sump to enter a heat exchanger.

13 . A propulsion system for an aircraft, the propulsion system comprising:
an electric motor comprising a stator and a rotor; a main shaft; a motor housing, wherein the main shaft and electric motor are located in the motor housing; an end bell assembly connected to the motor housing, the end bell assembly comprising:
a plate; and
a pump rotor configured to pump fluid from a sump;
a tilting mechanism configured to change an orientation of the propulsion system between a lift configuration and a cruise configuration, wherein a fluid inlet is positioned within the sump such that the fluid inlet remains in contact with a fluid in the sump in the lift configuration and the cruise configuration, wherein the fluid inlet is configured to distribute the fluid through the end bell assembly.

14 . The system of claim 13 , wherein the sump is configured to store the fluid for cooling the propulsion system.

15 . The system of claim 13 , wherein the sump is configured to store the fluid for lubricating the propulsion system.

16 . The system of claim 13 , wherein the fluid in the sump includes oil for cooling and lubricating the propulsion system.

17 . The system of claim 13 , wherein the sump is configured to store an amount of oil that is not more than three quarts.

18 . The system of claim 13 , wherein the end bell assembly further comprises a fluid inlet extending into the sump, wherein the fluid in the sump travels from the sump, through the fluid inlet, to the plate and to a heat exchanger.

19 . The system of claim 13 , further comprising an inverter assembly, wherein the motor housing is positioned between the inverter assembly and a propeller assembly.

20 . The system of claim 19 , further comprising a heat exchanger mounted to the inverter assembly, wherein the propeller assembly is configured to direct an air flow past the sump to enter the heat exchanger.

21 . A method of operating a propulsion system for an aircraft, the method comprising:
rotating a propeller of a propeller assembly by operating an electric motor comprising a stator and a rotor and operating a main shaft, wherein the propeller is coupled to the main shaft and the main shaft is driven by the rotor, wherein the electric motor and main shaft are located in a motor housing; and pumping fluid from a sump connected to the motor housing through an end bell assembly connected to the motor housing, wherein the fluid is pumped through a fluid inlet extending into the sump.

22 . The method of claim 21 , further comprising cooling the propulsion system with the pumped fluid.

23 . The method of claim 21 , further comprising lubricating the propulsion system with the pumped fluid.

24 . The method of claim 21 , further comprising cooling and lubricating the propulsion system with the pumped fluid.

25 . The method of claim 21 , further comprising pumping the fluid to a plate of the end bell assembly and to a heat exchanger.

26 . The method of claim 21 , further comprising operating a tilting mechanism configured to change an orientation of the propulsion system between a lift configuration and a cruise configuration.

27 . The method of claim 26 , further comprising pumping fluid through the fluid inlet in both the lift configuration and the cruise configuration.

28 . The method of claim 21 , wherein operating the propeller directs an air flow past the sump to enter a heat exchanger.

29 . An aircraft comprising:
a boom; a propulsion system coupled to the boom, the propulsion system comprising:
an electric motor comprising a stator and a rotor;
a main shaft;
a propeller assembly coupled to the main shaft;
a motor housing comprising a sump, wherein the main shaft and electric motor are located in the motor housing;
an end bell assembly connected to the motor housing, the end bell assembly comprising:
a plate; and
a fluid inlet extending into the sump, wherein the fluid inlet is configured to distribute fluid through the end bell assembly.

30 . The aircraft of claim 29 , wherein the aircraft is a vertical take off and landing (VTOL) aircraft.

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