Modular High-Torque Electric Motor Assembly for Direct Aircraft Drive
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Solution Overview
Problem
Traditional gas-powered engines used in aircraft pose hazards due to combustible fuel, exhibit performance variations with altitude, and produce environmentally unfriendly exhaust gases, necessitating a high-torque power system that mitigates these issues.
Innovation Solution
An electric motor assembly with multiple rotor and stator modules, integrated with an accessory gearbox and governor interface system, capable of delivering high torque (500 Nm to 3600 Nm) at low RPM without a reduction gearbox, and maintaining performance across varying altitudes, using high-voltage alternating current and liquid cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If gas-powered engines are used to drive propulsors, then high torque can be provided, but hazards arise due to combustible fuel, performance variations occur with altitude, and environmentally unfriendly exhaust gases are produced
Solution Approach 1:
The patent replaces the gas-powered mechanical engine system with an electric motor system. The electric motor receives electrical power and converts it directly to mechanical torque, eliminating the need for combustible fuel, exhaust systems, and mechanical moving parts associated with internal combustion engines. This substitution resolves the harmful factors while maintaining the torque output capability.
Solution Approach 2:
The patent changes the fundamental operating parameters from chemical energy combustion to electrical energy conversion. By using electric motors with controlled electrical inputs, the system achieves consistent torque output across varying altitudes, eliminating the performance variations inherent in gas-powered engines that depend on atmospheric conditions for combustion.
2Power
If traditional gas engines are used, then propulsion power is achieved, but the system complexity increases due to fuel storage, exhaust handling, and altitude compensation mechanisms
Solution Approach 1:
The patent extracts and removes the complex subsystems associated with gas-powered engines, including fuel storage tanks, fuel delivery systems, exhaust manifolds, catalytic converters, and altitude compensation mechanisms. The electric motor system requires only electrical power input and produces direct mechanical output, significantly reducing overall system complexity.
Solution Approach 2:
The electric motor assembly integrates multiple functions into a single compact unit. The motor provides propulsion torque, and the integrated accessory gearbox provides auxiliary power for various aircraft systems. This multi-functionality eliminates the need for separate systems for fuel management, exhaust handling, and altitude compensation required by traditional gas engines.
3Productivity
If high torque is required at low RPM without a reduction gearbox, then direct drive efficiency is improved, but the motor design complexity increases to achieve high torque density
Solution Approach 1:
The patent divides the motor into multiple independent rotor assemblies, each with its own stator module. This segmentation allows each rotor-stator pair to contribute to the total torque output, enabling high torque density without requiring a single overly complex motor design. The modular architecture simplifies manufacturing and maintenance while achieving the required torque at low RPM for direct drive application.
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
The electric motor assembly provides reliable, high-torque propulsion for aircraft without the hazards and performance variations associated with gas engines, while minimizing environmental impact through efficient energy conversion and cooling.
Implementation Method 1
one or more rotor assemblies, each rotor assembly having a rotor hub structure and associated permanent magnets mounted to the outer periphery of the rotor hub structure; and a main shaft. Each rotor assembly and corresponding stator module within which the associated rotor assembly rotates forms an independent motor module
Data Source
AI summary
An electric motor assembly to supply torque is disclosed where the assembly includes a stator modules having a plurality of stator windings, each stator winding configured to receive high-voltage, alternating current; a rotor assembly, each rotor assembly having a hub and plurality of magnets arranged on the hub, the plurality of magnets each having magnetic north and south poles where the plurality of magnets are arranged along an outer periphery of the hub to alternate the magnetic north and south poles; and a main shaft to supply the torque, wherein at least one of the one or more rotor assemblies is configured to rotate the main shaft, and the at least one of the one or more rotor assemblies is associated with and concentrically contained within the one or more stator modules, the at least one of the one or more rotor assemblies being rotatable relative to the one or more stator modules.