US 12,191,722 B2
High-torque electric motor assembly
David Sercombe, Arundel (AU); Michele D'Ercole, Arundel (AU); and Roei Ganzarski, Redmond, WA (US)
Assigned to MAGNIX USA, INC., Redmond, WA (US)
Filed by MagniX USA, Inc., Redmond, WA (US)
Filed on May 31, 2020, as Appl. No. 16/888,824.
Claims priority of provisional application 62/855,143, filed on May 31, 2019.
Claims priority of provisional application 62/855,147, filed on May 31, 2019.
Claims priority of provisional application 62/855,151, filed on May 31, 2019.
Prior Publication US 2020/0381984 A1, Dec. 3, 2020
Int. Cl. H02K 16/00 (2006.01); B64D 27/24 (2006.01); B64D 31/02 (2006.01); B64D 33/08 (2006.01); B64D 41/00 (2006.01); F16H 57/04 (2010.01); H02J 7/34 (2006.01); H02K 5/20 (2006.01); H02K 5/22 (2006.01); H02K 7/116 (2006.01); H02K 9/197 (2006.01); H02K 11/21 (2016.01); H02K 11/30 (2016.01); H02P 6/10 (2006.01); H02P 25/16 (2006.01); H02P 27/08 (2006.01)
CPC H02K 16/00 (2013.01) [B64D 27/24 (2013.01); B64D 31/02 (2013.01); B64D 33/08 (2013.01); B64D 41/00 (2013.01); F16H 57/0476 (2013.01); H02J 7/345 (2013.01); H02K 5/203 (2021.01); H02K 5/225 (2013.01); H02K 7/116 (2013.01); H02K 9/197 (2013.01); H02K 11/21 (2016.01); H02K 11/30 (2016.01); H02P 6/10 (2013.01); H02P 25/16 (2013.01); H02P 27/08 (2013.01); B64D 2221/00 (2013.01); H02K 2213/06 (2013.01)] 33 Claims
OG exemplary drawing
 
1. An electric motor assembly to supply torque, the assembly comprising:
an electric motor comprising:
one or more stator modules having a plurality of stator windings, each stator winding comprising a conductive wire having multiple loops to form a coil and configured to receive high-voltage, alternating current;
one or more rotor assemblies, 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;
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, concentrically contained within, and rotatable relative to the one or more stator modules; and
a cooling system comprising only a single coolant fluid loop having only a single coolant fluid that comprises oil to cool the electric motor, the single coolant fluid loop comprising at least one longitudinal channel formed in between at least one pair of conductive wire adjacent loops of the multiple loops forming the coil of a stator winding and configured to extend in the direction of a longitudinal rotational axis of the main shaft and in the direction of a longitudinal length of the stator winding, the at least one longitudinal channel configured to direct the single coolant fluid to flow through the at least one longitudinal channel of the stator winding and in direct contact with the adjacent conductive wire loops forming the at least one longitudinal channel in the coil of the stator winding, and
an integrated accessory gearbox configured to receive torque from the main shaft of the electric motor to drive a governor interface system, wherein the accessory gearbox includes one or more gears rotated by the main shaft and a fluid lubricant applied to the one or more gears in the accessory gearbox and wherein the governor interface system receives a speed reference from the main shaft and uses a hydraulic fluid to adjust a pitch of a propulsor element of an aircraft and wherein the same fluid that is used as the fluid lubricant to lubricate the one or more gears in the accessory gearbox is used as the hydraulic fluid in the governor interface system to adjust the pitch of the propulsor element,
wherein the same fluid used by the accessory gearbox as the fluid lubricant and used as the hydraulic fluid to adjust the pitch of the propulsor element is also used as the single coolant fluid to flow through the at least one longitudinal channel and in direct contact with the adjacent conductive wire loops forming the at least one longitudinal channel in the coil of the stator winding in the electric motor to cool the electric motor.