Abstract: In one embodiment, an advanced electric propulsion system comprises: a housing; an electric motor within the housing; a motor drive coupled to the motor; a thermal management system comprising: a manifold-mini-channel heat sink integrated into the housing, the manifold-mini-channel heat sink comprises: an inlet manifold having air inlets formed in front of the housing; a set of plurality of circumferentially grooved micro-channels formed in the housing and coupled to the air inlets and conductively thermally coupled to stator windings of the electric motor; an outlet manifold having an air outlets formed at a back of the housing and coupled to the set of plurality of circumferentially grooved micro-channels; wherein the electric motor comprises PEW stator windings that provide a low thermal resistance path from the stator of the electric motor to the housing; wherein the PEW stator windings comprise a high temperature tolerant thermally conductive electrical insulator.

Abstract: In one embodiment, an advanced electric propulsion system comprises: a housing; an electric motor within the housing; a motor drive coupled to the motor; a thermal management system comprising: a manifold-mini-channel heat sink integrated into the housing, the manifold-mini-channel heat sink comprises: an inlet manifold having air inlets formed in front of the housing; a set of plurality of circumferentially grooved micro-channels formed in the housing and coupled to the air inlets and conductively thermally coupled to stator windings of the electric motor; an outlet manifold having an air outlets formed at a back of the housing and coupled to the set of plurality of circumferentially grooved micro-channels; wherein the electric motor comprises PEW stator windings that provide a low thermal resistance path from the stator of the electric motor to the housing; wherein the PEW stator windings comprise a high temperature tolerant thermally conductive electrical insulator.

Abstract: In some examples, a stator assembly includes a stator body including a base portion and a plurality of stator teeth projecting radially inward from the base portion. The stator assembly further includes an electrically conductive member wound about a tooth of the plurality of stator teeth to define a winding about the tooth, the winding comprising a single layer of the conductive member and including a plurality of turns of the electrically conductive member, wherein the electrically conductive member has a thickness in the radial direction that is less than its width in a direction perpendicular to the radial direction.

Abstract: In one embodiment, an advanced electric propulsion system comprises: a housing; an electric motor within the housing; a motor drive coupled to the motor; a thermal management system comprising: a manifold-mini-channel heat sink integrated into the housing, the manifold-mini-channel heat sink comprises: an inlet manifold having air inlets formed in front of the housing; a set of plurality of circumferentially grooved micro-channels formed in the housing and coupled to the air inlets and conductively thermally coupled to stator windings of the electric motor; an outlet manifold having an air outlets formed at a back of the housing and coupled to the set of plurality of circumferentially grooved micro-channels; wherein the electric motor comprises PEW stator windings that provide a low thermal resistance path from the stator of the electric motor to the housing; wherein the PEW stator windings comprise a high temperature tolerant thermally conductive electrical insulator.

Abstract: A housing for a drive system. The housing defines a motor cavity, an electronics cold plate, an oil cavity, and a coolant cavity. The coolant cavity defines a first coolant flow path configured to provide cooling to the motor cavity and the oil cavity. The coolant cavity defines a second flow path configured to provide cooling to the motor cavity and the cold plate. The housing defines a coolant inlet and a coolant outlet fluidically coupled to the first coolant flow path and the second coolant flow path, such that the first coolant flow path and the second coolant flow path are parallel fluid paths. In some applications the coolant paths can be connected in series. In some examples, the housing is configured to cause a counter-flow heat exchange between an oil flowing in the oil cavity and a coolant flowing in the first coolant flow path.

Abstract: In one embodiment, an advanced electric propulsion system comprises: a housing; an electric motor within the housing; a motor drive coupled to the motor; a thermal management system comprising: a manifold-mini-channel heat sink integrated into the housing, the manifold-mini-channel heat sink comprises: an inlet manifold having air inlets formed in front of the housing; a set of plurality of circumferentially grooved micro-channels formed in the housing and coupled to the air inlets and conductively thermally coupled to stator windings of the electric motor; an outlet manifold having an air outlets formed at a back of the housing and coupled to the set of plurality of circumferentially grooved micro-channels; wherein the electric motor comprises PEW stator windings that provide a low thermal resistance path from the stator of the electric motor to the housing; wherein the PEW stator windings comprise a high temperature tolerant thermally conductive electrical insulator.

Abstract: In some examples, a stator assembly includes a stator body including a base portion and a plurality of stator teeth projecting radially inward from the base portion. The stator assembly further includes an electrically conductive member wound about a tooth of the plurality of stator teeth to define a winding about the tooth, the winding comprising a single layer of the conductive member and including a plurality of turns of the electrically conductive member, wherein the electrically conductive member has a thickness in the radial direction that is less than its width in a direction perpendicular to the radial direction.

Abstract: A traction drive system for a vehicle includes a housing, a high-speed motor, a motor controller, a transmission, a cooling system, and a lubricating oil system. The housing defines a motor cavity, an electronics cavity, an oil cavity, and a cooling fluid cavity. The cooling fluid cavity is thermally coupled to each of the motor, electronics, and oil cavities. The high-speed motor is substantially within the motor cavity and coupled to a lubricating oil system fluidically coupled to the oil cavity. The motor controller includes electronics within the electronics cavity. The transmission is mechanically coupled to the high-speed motor and coupled to the lubricating oil system fluidically coupled to the oil cavity. The cooling system is fluidically coupled to the cooling fluid cavity and configured to cool the high-speed motor, the motor controller, and the lubricating oil system.

Abstract: A traction drive system for a vehicle includes a housing, a high-speed motor, a motor controller, a transmission, a cooling system, and a lubricating oil system. The housing defines a motor cavity, an electronics cavity, an oil cavity, and a cooling fluid cavity. The cooling fluid cavity is thermally coupled to each of the motor, electronics, and oil cavities. The high-speed motor is substantially within the motor cavity and coupled to a lubricating oil system fluidically coupled to the oil cavity. The motor controller includes electronics within the electronics cavity. The transmission is mechanically coupled to the high-speed motor and coupled to the lubricating oil system fluidically coupled to the oil cavity. The cooling system is fluidically coupled to the cooling fluid cavity and configured to cool the high-speed motor, the motor controller, and the lubricating oil system.

Abstract: A winding system may include a plurality of metal plates including the same shape and size, such that the plates are stacked, and each of the plurality of metal plates is reversely positioned with respect to a gap pattern in an adjacent one of the plurality of metal plates. The plates are simultaneously brazed together while flow of molten brazing material is constrained by grooves formed on brazing tabs of the plates.

Abstract: A winding system may include a plurality of metal plates including the same shape and size, such that the plates are stacked, and each of the plurality of metal plates is reversely positioned with respect to a gap pattern in an adjacent one of the plurality of metal plates. The plates are simultaneously brazed together while flow of molten brazing material is constrained by grooves formed on brazing tabs of the plates.

Abstract: A winding system may include a plurality of metal plates including the same shape and size, such that the plates are stacked, and each of the plurality of metal plates is reversely positioned with respect to a gap pattern in an adjacent one of the plurality of metal plates. The plates are simultaneously brazed together while flow of molten brazing material is constrained by grooves formed on brazing tabs of the plates.

Abstract: An airflow system may comprise a fan radially mounted on a motor with a first plurality of fins surrounding the motor disposed to provide airflow in a first direction, and a second plurality of fins surrounding the motor disposed to provide airflow in a second direction. A housing may surround the plurality of fins.

Abstract: A winding system may include a plurality of metal plates including the same shape and size, such that the plates are stacked, and each of the plurality of metal plates is reversely positioned with respect to a gap pattern in an adjacent one of the plurality of metal plates. The plates are simultaneously brazed together while flow of molten brazing material is constrained by grooves formed on brazing tabs of the plates.

Abstract: A motor cooling system is provided comprising an electric motor including a rotor having first and second axial ends, and a stator having first and second axial ends, a motor housing surrounding the motor including an air chamber extending around the motor and axially along the motor length, a motor enclosure enveloping the motor housing, and a cooling fan radially mounted to the motor enclosure and adapted to operatively cool said electric motor.

Abstract: A boosting AC-to-DC converter An AC-to-DC converter may include a main rectifier, a first auxiliary rectifier, a second auxiliary rectifiers and a transformer assembly. The transformer assembly may include a set of primary windings arranged in a first multiphase configuration and connected to the main rectifier, a first set of secondary windings arranged in a second multiphase relationship and connected to the first auxiliary rectifier and a second set of secondary windings arranged in a third multiphase configuration and connected to the second auxiliary rectifier. The second multiphase configuration of the first set of secondary windings and the third multiphase configuration of the second set of secondary windings may be in phase shifting relationships relative to the first multiphase configuration of the set of primary windings.

Abstract: Current imbalance may be detected in a 3-phase power system by monitoring current output between two points of a phase signal provided along wire pairs from an inverter to a motor. In some embodiments, each wire of a wire pair leading to the motor from the inverter may be provided with a line current sensor. A comparison of current output from each wire in the wire pair may be performed to determine if a current imbalance is present. In some embodiments, a phase current sensor may be coupled to a phase input of the inverter. Failures in the 3-phase system may be detected by measuring the output from each phase current sensor for imbalanced distribution of power output. In some embodiments, the output from the phase current sensors may be compared to an output of a line current sensor along the same phase for current imbalances or harness failures.

Abstract: A system for generating and supplying electrical power to DC loads on an aircraft may include a permanent magnet machine (PMM) generating an output voltage at a plurality of output terminals and a solid-state switch connected to each of the output terminals to short-circuit the output terminal when the switch is ON. A control unit may be configured to detect an unbalanced fault in the system and, responsively to said detection, to close all of the switches simultaneously to convert the unbalanced fault to a balanced fault so that DC currents are precluded from circulating within the PMM.

Abstract: An airflow system may comprise a fan radially mounted on a motor with a first plurality of fins surrounding the motor disposed to provide airflow in a first direction, and a second plurality of fins surrounding the motor disposed to provide airflow in a second direction. A housing may surround the plurality of fins.

Abstract: A winding system may include a plurality of metal plates including the same shape and size, such that the plates are stacked, and each of the plurality of metal plates is reversely positioned with respect to a gap pattern in an adjacent one of the plurality of metal plates.