Abstract: An electrical propulsion system for a vertical take-off and landing (VTOL) aircraft comprises an electrical motor assembly and an inverter assembly. The inverter assembly comprises a housing, a capacitor assembly, at least one printed circuit board assembly (PCBA), and a plurality of positioning pins. The capacitor assembly comprises a center hole, at least one capacitor, a capacitor housing having at least one busbar, and a plurality of through holes in the capacitor housing. The capacitor assembly and the at least one PCBA are positioned inside the housing. The plurality of positioning pins pass through the through the plurality of through holes of the capacitor housing and the at least one PCBA and are connected to the housing.

Abstract: An electrical propulsion system includes an electrical motor configured to drive one or more propellers of the aircraft, a capacitor configured to stabilize a direct current (DC) bus voltage, a first inverter circuit coupled to the capacitor and configured to convert the DC bus voltage to alternate current (AC) voltages to drive a first set of stator windings of the electrical motor, in response to a first pulse width modulation (PWM) vector, and a second inverter circuit coupled to the capacitor and configured to convert the DC bus voltage to AC voltages to drive a second set of stator windings of the electrical motor, in response to a second PWM vector. The first PWM vector and the second PWM vector are substantially equal and opposite vectors.

Abstract: A power distribution system for an electric aircraft includes a first electric propulsion unit comprising at least two power stages; a first battery pack electrically connected to a first power stage of the at least two power stages; a second battery pack electrically connected to a second power stage of the at least two power stages; and a control system configured to control the first battery pack, the second battery pack, the first power stage, and the second power stage to transfer power from the first battery pack to the second battery pack through the first power stage and the second power stage.

Abstract: A power distribution system for an electric aircraft includes a first electric propulsion unit comprising at least two power stages; a first battery pack electrically connected to a first power stage of the at least two power stages; a second battery pack electrically connected to a second power stage of the at least two power stages; and a control system configured to control the first battery pack, the second battery pack, the first power stage, and the second power stage to transfer power from the first battery pack to the second battery pack through the first power stage and the second power stage.

Abstract: Embodiments of cooling a motor controlling using a motor are disclosed. In some embodiments, a system includes an electric motor including at least one rotor with integrated features positioned and configured to pull air into and through the electric motor. The system also includes at least one motor controller each comprising a heat sink positioned in an air intake path from a source of air to the electric motor. A method of manufacturing the system includes arranging at least one motor controller and at least one electric motor, coupling the at least one motor controller and at least one electric motor via a flexible duct, and adapting the arrangement of the at least one motor controller and the at least one electric motor to passively provide cooling via airflow through the at least one motor controller and at least one electric motor in proportion to a load on the at least one electric motor.

Abstract: Embodiments of a modular motor assembly are disclosed. In some embodiments, a motor comprises a plurality of modular magnetic units, where each of the modular magnetic units includes at least one rotor and at least one stator. The motor further comprises a plurality of structural segments each adapted to support a stator of a corresponding one of the modular magnetic units, where each of the structural segments interlocks with a next structural segment to form a stack. A method of manufacturing a motor includes arranging a selected number of modular magnetic units, coupling the selected number of modular magnetic units to a shaft, coupling the selected number of modular magnetic units to respective structural segments, and forming electrical connections to apply three-phase voltage to stator windings of the modular magnetic units.

Abstract: Non-invasive rubbing detection for motors is disclosed. In an embodiment, a method of detecting rubbing on a stator of a motor includes providing an electrical conductor on the stator, (the electrical conductor has a first end and a second end). The method further includes determining that there is rubbing on a surface of the stator, including by probing the first end and the second end to determine whether there is an electrical connection across the electrical conductor, and determining that there is rubbing on the stator if there is no electrical connection. In an embodiment, the electrical conductor is disposed on the surface of the stator by etching away conductive foil to form the electrical conductor, and providing the electrical conductor.

Abstract: Embodiments of cooling a motor controlling using a motor are disclosed. In some embodiments, a system includes an electric motor including at least one rotor with integrated features positioned and configured to pull air into and through the electric motor. The system also includes at least one motor controller each comprising a heat sink positioned in an air intake path from a source of air to the electric motor. A method of manufacturing the system includes arranging at least one motor controller and at least one electric motor, coupling the at least one motor controller and at least one electric motor via a flexible duct, and adapting the arrangement of the at least one motor controller and the at least one electric motor to passively provide cooling via airflow through the at least one motor controller and at least one electric motor in proportion to a load on the at least one electric motor.

Abstract: Embodiments of a modular motor assembly are disclosed. In some embodiments, a motor comprises a plurality of modular magnetic units, where each of the modular magnetic units includes at least one rotor and at least one stator. The motor further comprises a plurality of structural segments each adapted to support a stator of a corresponding one of the modular magnetic units, where each of the structural segments interlocks with a next structural segment to form a stack. A method of manufacturing a motor includes arranging a selected number of modular magnetic units, coupling the selected number of modular magnetic units to a shaft, coupling the selected number of modular magnetic units to respective structural segments, and forming electrical connections to apply three-phase voltage to stator windings of the modular magnetic units.

Abstract: Embodiments of a modular motor assembly are disclosed. In some embodiments, a motor comprises a plurality of modular magnetic units, where each of the modular magnetic units includes at least one rotor and at least one stator. The motor further comprises a plurality of structural segments each adapted to support a stator of a corresponding one of the modular magnetic units, where each of the structural segments interlocks with a next structural segment to form a stack. A method of manufacturing a motor includes arranging a selected number of modular magnetic units, coupling the selected number of modular magnetic units to a shaft, coupling the selected number of modular magnetic units to respective structural segments, and forming electrical connections to apply three-phase voltage to stator windings of the modular magnetic units.

Abstract: A system for measuring temperature in an electric motor includes an interface communicatively coupled to a motor and a processor coupled to the interface. In various embodiments, the processor is configured to obtain access to a temperature-measuring electrical path, where the temperature-measuring electrical path rotates relative to a magnetic field, and the temperature-measuring electrical path has no net induced voltage due to magnetic field as the temperature-measuring electrical path rotates relative to the magnetic field. The processor may be further configured to determine a resistance associated with the temperature-measuring electrical path, and determine a temperature of the motor based at least in part on the resistance.