Dual-Rotor Motor Assembly With Shared Cooling and Control
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Solution Overview
Problem
Conventional motor assemblies for propulsion systems, such as those in urban mobility vehicles and rotorcraft, face challenges in efficiently managing multiple propulsion directions and speeds with existing direct drive electrical machines, often resulting in complex and bulky configurations due to separate components for each rotor and stator.
Innovation Solution
A dual rotor motor assembly with a shared housing containing independent first and second rotors, stators, an electronics module, and a cooling module, allowing for simultaneous control of multiple output shafts and propellers with unified electronics and cooling systems, reducing complexity and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate components are used for each rotor and stator in conventional motor assemblies, then each component can operate independently, but the overall device complexity and size increase
Solution Approach 1:
The patent combines multiple rotors and stators into a single integrated motor assembly where multiple rotors are mounted on a common output shaft and share a common stator structure. This merging approach maintains the independent operation capability of each rotor-stator pair while significantly reducing the overall device complexity and size compared to using completely separate motor components.
Solution Approach 2:
The common output shaft serves multiple functions by simultaneously supporting and transmitting torque from multiple rotors. Similarly, the shared stator structure provides magnetic fields for multiple rotors while reducing the total number of stator components needed. This multi-functionality approach reduces component count while preserving independent control capabilities.
2Ease of operation
If multiple separate motor assemblies are used to control multiple propellers, then each propeller can be controlled independently, but the overall system size and weight increase
Solution Approach 1:
The patent merges multiple motor assemblies into a single integrated unit where multiple rotors share a common output shaft and housing. This consolidation maintains independent control capability for each rotor through separate electronics module control while significantly reducing the total weight compared to using multiple separate motor assemblies, as the shared components eliminate redundant structures.
3Device complexity
If unified electronics and cooling systems are used in the dual rotor assembly, then device complexity is reduced, but thermal management challenges increase
Solution Approach 1:
The patent merges the cooling systems into a unified approach where a single cooling module serves both rotors and stators through a common cooling circuit. This integration reduces the number of separate cooling systems needed while effectively managing thermal loads from multiple power-generating components through shared coolant flow paths.
Solution Approach 2:
The unified cooling module performs multiple thermal management functions simultaneously, cooling multiple rotors, multiple stators, and potentially the electronics module through a single integrated system. This multi-functional cooling approach reduces overall system complexity while maintaining effective temperature control across all components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enables a compact, efficient propulsion system capable of managing multiple propulsion directions and speeds, reducing wiring and transmission line effects, while maintaining performance by allowing each rotor to operate independently with precise control and cooling.
Implementation Method 1
electrical machines direct drive for propulsion systems... rotor magnets rotate relative to a fixed stator to drive a rotor
Data Source
AI summary
A motor assembly including a housing, a first rotor (R1, R1′) and a second rotor (R2, R2′) provided in the housing. The first rotor (R1, R1′) is configured to drive a first output shaft, and the second rotor is configured to drive a second output shaft.