Electric motor propulsion system for an aircraft

Patent metadata

Field	Value
Publication number	US-12583608-B2
Application number	US-202318196711-A
Country	US
Kind code	B2
Filing date	May 12, 2023
Priority date	May 12, 2023
Publication date	Mar 24, 2026
Grant date	Mar 24, 2026

Abstract

An assembly for a propulsion system of an aircraft includes an electric motor, a first gearbox module, a second gearbox module, and a propeller. The electric motor includes a rotor. The rotor includes a first axial end and a second axial end. The first gearbox module includes a first gear assembly. The first gear assembly is coupled to the first axial end. The second gearbox module includes a second gear assembly. The second gear assembly is coupled to the second axial end. The propeller is coupled to the first gear assembly. The first gear assembly is configured to drive rotation of the propeller in response to rotation of the rotor.

First claim

The invention claimed is:

1 . An assembly for a propulsion system of an aircraft, the assembly comprising:
an electric motor including a rotor, the rotor includes a first axial end and a second axial end; a first gearbox module including a first gear assembly, the first gear assembly is coupled to the first axial end; a second gearbox module including a second gear assembly, the second gear assembly is coupled to the second axial end; and a propeller coupled to the first gear assembly, the first gear assembly is configured to drive rotation of the propeller in response to rotation of the rotor; wherein the electric motor includes a motor housing, the motor housing extends between and to a first axial motor end and a second axial motor end, the second axial motor end opposite the first axial motor end, the motor housing includes a first flange at the first axial motor end and a second flange at the second axial motor end, the first flange is mounted to the first gearbox module, and the second flange is mounted to the second gearbox module.

2 . The assembly of claim 1 , wherein the rotor includes a rotor body, a first output shaft, and a second output shaft, the rotor body extends between and to the first axial end and the second axial end, the first output shaft is disposed at the first axial end, and the second output shaft is disposed at the second axial end.

3 . The assembly of claim 2 , wherein the first output shaft and the second output shaft are rotatable about a rotational axis.

4 . The assembly of claim 3 , wherein the first output shaft and the second output shaft rotate are rotatable together about the rotational axis.

5 . The assembly of claim 1 , wherein the first gear assembly is a reduction gear assembly.

6 . The assembly of claim 1 , further comprising a plurality of auxiliary loads coupled to the second gear assembly, the second gear assembly configured to drive the plurality of auxiliary loads in response to rotation of the rotor.

7 . The assembly of claim 6 , wherein the plurality of auxiliary loads includes an air compressor.

8 . The assembly of claim 1 , wherein the propeller is a variable-pitch propeller.

9 . A method for forming an electric motor propulsion system for an aircraft, the method comprising:
for a propulsion system including a first gearbox module, a second gearbox module, and a gas turbine engine, the first gearbox module including a first gear assembly, the second gearbox module including a second gear assembly, the gas turbine engine including at least one rotational assembly coupled with the first gear assembly and the second gear assembly, the at least one rotational assembly rotatable about a rotational axis to drive the first gear assembly and the second gear assembly, performing the steps of:
removing the gas turbine engine from an installation location of the propulsion system; and
forming the electric motor propulsion system by installing an electric motor in the propulsion system at the installation location subsequent to removing the gas turbine engine from the propulsion system, and coupling a rotor of the electric motor with the first gear assembly and the second gear assembly;
wherein the electric motor includes a motor housing, the motor housing extends between and to a first axial motor end and a second axial motor end, the second axial motor end opposite the first axial motor end, the motor housing includes a first flange at the first axial motor end and a second flange at the second axial motor end, the first flange is mounted to the first gearbox module, and the second flange is mounted to the second gearbox module.

10 . The method of claim 9 , wherein the at least one rotational assembly includes a first rotational assembly and a second rotational assembly, the first rotational assembly coupled to the first gear assembly and the second rotational assembly coupled to the second gear assembly.

11 . The method of claim 9 , wherein the rotor includes a first output shaft and a second output shaft, and coupling the rotor of the electric motor with the first gear assembly and the second gear assembly includes coupling the first shaft with the first gear assembly and coupling the second shaft with the second gear assembly.

12 . An aircraft propulsion system comprising:
an electric motor including a rotor rotatable about a rotational axis; a first gearbox module including a first gear assembly, the first gear assembly is coupled to rotor; a second gearbox module including a second gear assembly, the second gear assembly is coupled to the rotor; a propulsor coupled to the first gear assembly, the first gear assembly is configured to drive rotation of the propulsor in response to rotation of the rotor; and a plurality of auxiliary loads coupled to the second gear assembly, the second gear assembly configured to drive the plurality of auxiliary loads in response to rotation of the rotor; wherein the electric motor includes a motor housing, the motor housing extends between and to a first axial end and a second axial end, the second axial end opposite the first axial end, the motor housing includes a first flange at the first axial end and a second flange at the second axial end, the first flange is mounted to the first gearbox module, and the second flange is mounted to the second gearbox module.

13 . The aircraft propulsion system of claim 12 , wherein the rotor includes a rotor body, a first output shaft, and a second output shaft, the rotor body extends between and to a first axial end and a second axial end, the first output shaft is disposed at the first axial end, the first output shaft is coupled to the first gear assembly, the second output shaft is disposed at the second axial end, and the second output shaft is coupled to the second gear assembly.

14 . The aircraft propulsion system of claim 13 , wherein the first output shaft and the second output shaft are rotatable about the rotational axis.

15 . The aircraft propulsion system of claim 13 , wherein the first output shaft and the second output shaft are rotatable together about the rotational axis.

16 . The aircraft propulsion system of claim 12 , wherein the electric motor is positioned axially between the first gearbox module and the second gearbox module.

17 . The assembly of claim 1 , wherein
the first gearbox module comprises a reduction gearbox module; the second gearbox module comprises an accessory gearbox module; and the electric motor is positioned axially between the reduction gearbox module and the accessory gearbox module.

18 . The assembly of claim 1 , wherein the motor housing extends circumferentially about and axially along the electric motor.

Assignees

• Pratt & Whitney Canada

Inventors

• Durocher Eric S
• Labrecque Michel
• Spierling Todd A

Classifications

• H02K7/14

  Structural association with mechanical loads, e.g. with hand-held machine tools or fans (with fan or impeller for cooling the machine H02K9/06) · CPC title

• H02K7/116

  with gears · CPC title

• H02K7/006

  Structural association of a motor or generator with the drive train of a motor vehicle · CPC title

• H02K7/003

  Couplings; Details of shafts (means for mounting rotors on shafts H02K1/28) · CPC title

• F16H2057/02082

  for application in vehicles other than propelling, e.g. adjustment of parts · CPC title