Abstract: A power distribution circuit for an electrically powered aircraft includes a plurality of batteries and a plurality of electric propulsion systems. A plurality of isolated power distribution circuits each couple a battery of the plurality of batteries to two or more electric propulsion systems. The plurality of electric propulsion systems are positioned on the aircraft to apply balanced forces to the aircraft such that in the event of a failure, the aircraft remains stable and only experiences a loss in altitude or speed.

Abstract: Techniques described here provide a rotor and a method of making a rotor. In an embodiment, a method of making a rotor includes forming a magnet array by assembling a plurality of magnets into the magnet array, providing pre-preg adjacent to the magnet array, co-curing the magnet array with the pre-preg, and magnetizing the magnet array subsequent to the formation of the magnet array.

Abstract: At least an output shaft angle associated with an output shaft is initialized to a known value where the output shaft is coupled to a motor shaft via a set of one or more gears. A direction of rotation associated with the motor shaft is determined using a plurality of discrete Hall sensors in the motor and the output shaft angle is updated using an incremental value and the direction of rotation.

Abstract: A coupled battery and motor controller thermal management system is disclosed. In various embodiments, a motor controller and a heat sink are coupled thermally to a battery. At least a portion of waste heat generated by the motor controller is transferred to the thermal mass of the battery during at least a first mode of operation in which a relatively low amount of ambient air flows through the heat sink.

Abstract: A power delivery system includes a controller, configured to receive a voltage indication signal indicating a measured voltage of a battery management system and to determine whether first and second diodes of the battery management system are faulty based on the voltage indication signal. The controller is also configured to respectively receive first and second current indication signals from first and second current sensors of the battery management system and to determine whether the first and second diodes of the first battery management system are faulty based on the first and second current indication signals.

Abstract: Techniques described here provide a rotor and a method of making a rotor. In an embodiment, a method of making a rotor includes forming a magnet array by assembling a plurality of magnets into the magnet array, providing pre-preg adjacent to the magnet array, co-curing the magnet array with the pre-preg, and magnetizing the magnet array subsequent to the formation of the magnet array.

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 provide an electric aircraft with a plurality of lift fan assemblies that are configured to provide vertical lift, and one or more pusher propellers that are configured to provide forward thrust. The lift fan assemblies may be coupled to the wings of the aircraft via one or more support structures, and the wings may be coupled to an upper region of the fuselage. The pusher propeller(s) may be coupled to a tailing end of the fuselage. The lift fan assemblies and the pusher propeller(s) may provide thrust and movement in directions that are orthogonal to one another. A control system coupled to the aircraft may control the lift fan assemblies and the one or more pusher propellers to activate, increase in power, and decrease in power. The lift fan assemblies and the one or more pusher propellers may be operated separately, and may be active at different times.

Abstract: An electrically powered vehicle includes a plurality of batteries and a plurality of DC to DC converters, each coupled to a respective battery of the plurality of batteries. Each DC to DC converter transfers power from a respective battery to a common DC bus. The common DC bus is coupled to a plurality of inverter circuits that convert the DC power to AC power. A plurality of electric motors receive power from the plurality of inverter circuits to propel the vehicle. During a regenerative event, the DC to DC converters can transfer power from the motors back to the batteries. In response to the failure of a battery, the DC to DC converters can isolate the remainder of the system from the failure.

Abstract: An electrically powered vehicle comprises a DC bus and a plurality of batteries, each coupled in parallel to the DC bus. At least one switch is coupled in series between at least one battery of the plurality of batteries and the DC bus and a plurality of inverter circuits are each coupled in parallel to the DC bus. A plurality of motors are each coupled to a respective inverter circuit of the plurality of inverter circuits. In various embodiments the electrically powered vehicle further comprises a plurality of switches, each switch coupled in series between a respective battery of the plurality of batteries.

Abstract: Method and assembly for producing a magnet. A method of manufacturing a magnet includes transferring magnetic powder into a die cavity. The die cavity has a first side and a second side opposite to the first side. First magnetic flux lines are induced to extend into the magnetic powder through the first side and orthogonal to the first side. The first magnetic flux lines extend out of the magnetic powder through a top surface of the magnetic powder. Second magnetic flux lines are induced to extend into the magnetic powder through the second side and orthogonal to the second side. The second magnetic flux lines extend out of the magnetic powder through the top surface of the magnetic powder. Pressure is applied to the magnetic powder disposed within the die cavity.

Abstract: A system is disclosed to detect failure of a diode that is connected in series with a battery and a contactor or other switch configured to connect the battery to a load when the contactor or other switch is in a closed position and to isolate the battery from the load when the contactor or other switch is in an open position. In various embodiments, the system includes a high value resistor connected between the anode terminal of the diode and ground, the connection to the anode terminal being on a load side of the contactor or other switch; and a voltage meter configured to measure a voltage across the high value resistor at least during a test in which a voltage is applied to a bus associated with the load while the contactor or other switch is in the open position.

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: At least an output shaft angle associated with an output shaft is initialized to a known value where the output shaft is coupled to a motor shaft via a set of one or more gears. A direction of rotation associated with the motor shaft is determined using a plurality of discrete Hall sensors in the motor and the output shaft angle is updated using an incremental value and the direction of rotation.

Abstract: At least an output shaft angle associated with an output shaft is initialized to a known value where the output shaft is coupled to a motor shaft via a set of one or more gears. A direction of rotation associated with the motor shaft is determined using a plurality of discrete Hall sensors in the motor and the output shaft angle is updated using an incremental value and the direction of rotation.

Abstract: A magnetic spring input device is disclosed. In various embodiments, an input device as disclosed includes a manual input structure movably coupled to a base assembly; and a non-stationary magnet fixedly coupled to the manual input structure; a stationary magnet coupled to the base assembly in a manner that is fixed with respect to at least a first input axis of the input device, the stationary magnet being coupled to the base assembly with a first magnetic pole having a first magnetic polarity is oriented opposite a corresponding magnetic pole of the non-stationary magnet having the first magnetic polarity, in a position that is adjacent to but offset from the non-stationary magnet when the manual input structure is in a neutral position.

Abstract: A conductor in composite is disclosed. In various embodiments, an electrically conductive structure, such as an electrically conductive metal, is sandwiched between insulating material and two or more layers of fiber reinforced composite material, to form a stack that is used to form a composite structure that includes the electrically conductive layer. The layer may comprise an electrical line, trace, bus, etc. to conduct electricity from one location to another within the composite structure, such as to connect a battery or other power source at one location to an electrical load at another location.

Abstract: One or more converters are selected from a plurality of converters to enable where there is a plurality of energy storage modules electrically connected together in series. Each converter is electrically connected to a corresponding energy storage module. The selected converters are enabled where in response to being enabled, an enabled converter converts an input, from its corresponding energy storage module, at a first voltage level into an output at a second voltage level and the outputs of the enabled converters are electrically combined to produce a combined output. The combined output is compared against a desirable operating region defined by an upper threshold and a lower threshold. In response to the combined output being outside of the desirable operating region, the number of enabled converters is adjusted.

Abstract: Techniques disclosed here provide an array of magnets and a method of manufacturing a magnet array. In an embodiment, the array of magnets includes a plurality of three-pole magnets arranged in an array in which each three-pole magnet comprising the array is adjacent to one or more other three-pole magnets comprising the array. For example, a three-pole magnet comprises a first surface comprising a first magnetic pole having a first magnetic polarity, a second surface that is adjacent to and at least partly orthogonal to the first surface and which comprises a second magnetic pole having a second magnetic polarity that is opposite the first magnetic polarity, and a third surface that is adjacent to the first surface at an end substantially opposite the second surface and which comprises a third magnetic pole having the second magnetic polarity.

Abstract: Techniques to monitor a ground network are disclosed. In various embodiments, a test current is supplied to a ground connection from an electronic subsystem to a star point of a ground network. A voltage meter is used to read the potential difference between the ground connection and the voltage reference while the test current is being supplied to the ground connection to the star point of the ground network. The read potential difference is used to compute a computed resistance associated with the ground connection to the star point of the ground network. The computed resistance is used to determine that a detection criterion associated with the health of the ground connection to the star point of the ground network has been satisfied.