Integrated Stator Assembly with Dielectric Mandrel for eVTOL Propulsion
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Solution Overview
Problem
Electric multi-propulsion systems, such as eVTOL aircraft, face challenges with volumetric, gravimetric, and thermal constraints that limit the efficiency and performance of propulsor units, necessitating innovative designs that reduce weight, drag, and thermal issues while maintaining efficient flight capabilities.
Innovation Solution
The integration of a stator assembly with a mandrel made of dielectric material and electrically conductive windings, where the windings are wound in a specific configuration to maximize magnetic force exertion on rotor magnets, forming a compact and efficient propulsion unit that reduces drag and weight, and includes a cooling mechanism for internal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the propulsor units are designed with conventional configurations, then the structural integrity and magnetic force generation are maintained, but the weight and drag increase, reducing flight efficiency
Solution Approach 1:
The patent combines the stator and rotor into a single integrated propulsor unit, eliminating the need for separate motor housing and mounting structures. This merging reduces the overall weight and volumetric footprint while maintaining the magnetic force generation capability, directly addressing the contradiction between flight efficiency and propulsor weight
2Productivity
If the propulsor units are designed with conventional configurations, then the magnetic force generation is maintained, but the volumetric footprint increases, limiting aircraft design flexibility
Solution Approach 1:
The patent nests the rotor magnets within the stator windings structure, creating a compact configuration where the rotor is effectively embedded within the stator assembly. This nesting approach minimizes the volumetric footprint while maintaining the magnetic interaction necessary for propulsion, resolving the contradiction between propulsion efficiency and propulsor volume
3Power
If the windings are configured to maximize magnetic force, then the thrust output is improved, but the energy losses and thermal issues increase
Solution Approach 1:
The patent employs skewing the windings at specific angles relative to the rotor magnets, creating localized optimization of the magnetic field distribution. This local quality adjustment maximizes the useful magnetic force in critical regions while reducing eddy current losses and thermal generation, thereby improving thrust output without proportionally increasing energy losses
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 reduced drag, weight reduction, and extended flight times by minimizing the energy demand on the propulsion system, allowing for more efficient and reliable operation in various flight conditions, including hovering and high-turbulence situations.
Implementation Method 1
electrically conductive stator windings wound upon the mandrel, each winding of the plurality of windings including a plurality of turns traversing the first cylindrical surface
Implementation Method 2
maximize magnetic force exertion on rotor magnets
Implementation Method 3
mandrel of dielectric material, wherein the mandrel includes a first cylindrical surface coaxial to an axis of rotation of the rotor
Data Source
AI summary
An integrated stator assembly incorporated in an electric motor including a rotor that includes a plurality of rotor magnets, each rotor magnet of the plurality of magnets having a polar axis running from a rotor magnet south pole to a rotor magnet north pole. The assembly comprising a mandrel of dielectric material, wherein the mandrel includes a first cylindrical surface coaxial to an axis of rotation of the rotor, an upper edge, and a lower edge. A plurality of electrically conductive stator windings wound upon the mandrel, each winding of the plurality of windings including a plurality of turns traversing the first cylindrical surface, wherein each turn of the plurality turns further comprises a first upper section disposed on the first cylindrical surface, wherein the first upper section intersects the upper edge of the mandrel, and the first upper section forms a first angle to the axis of rotation.