Abstract: A lift fan includes a stator which is configured to output a magnetic field. The lift fan also includes a first housing which in turn includes a blade, a second housing, and a magnet array. The magnet array is coupled to either the first housing or the second housing and the housing, which is coupled to the magnet array, rotates in response to the magnet array responding magnetically to the magnetic field output by the stator.

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: A lightweight and efficient electrical machine element including a method of manufacture providing a stator winding for an electric machine which has a large portion of its volume containing electrically conductive strands and a small portion of its volume containing of an encapsulant material. The stator winding includes winding of a first phase by shaping a portion of a bundle of conductive strands into an overlapping, multi-layer arrangement. Winding of successive phases occurs with further bundles of conductor strands around the preceding phases constructed into similar overlapping, multi-layer arrangements. The multiple phases are impregnated with the encapsulant material using dies to press the bundles into a desired form while expelling excess encapsulant prior to the curing of the encapsulant material. The encapsulated winding is removed from the dies after the encapsulant has cured. The encapsulant coating on the strands may be activated using either heat or solvent.

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 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: 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 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 lift fan includes a stator which is configured to output a magnetic field. The lift fan also includes a first housing which in turn includes a blade, a second housing, and a magnet array. The magnet array is coupled to either the first housing or the second housing and the housing, which is coupled to the magnet array, rotates in response to the magnet array responding magnetically to the magnetic field output by the stator.

Abstract: A lift fan includes a stator which is configured to output a magnetic field. The lift fan also includes a first housing which in turn includes a blade, a second housing, and a magnet array. The magnet array is coupled to either the first housing or the second housing and the housing, which is coupled to the magnet array, rotates in response to the magnet array responding magnetically to the magnetic field output by the stator.

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: Described embodiments provide a rotor mounting boom assembly for a personal aircraft. The rotor mounting boom assembly includes a rotor mounting boom releasably attachable to a wing of the personal aircraft, one or more vertical lift rotors, and one or more rotor controller assemblies. Controller assemblies for each rotor are positioned on the rotor mounting booms such that downwash from the rotor causes increased airflow across the controller assembly to cool the controller assembly components. A rotor controller enclosure includes an air inlet and an air outlet to allow airflow through the enclosure to cool the controller components. The air inlet is positioned relative to the path of the rotor blades such that the downwash from the rotor that flows into the air inlet is maximized. The structure of the enclosure includes features for increasing the airflow through the enclosure.

Abstract: A lift fan includes a stator which is configured to output a magnetic field. The lift fan also includes a first housing which in turn includes a blade, a second housing, and a magnet array. The magnet array is coupled to either the first housing or the second housing and the housing, which is coupled to the magnet array, rotates in response to the magnet array responding magnetically to the magnetic field output by the stator.

Abstract: In various embodiments, a skewed Halbach array rotor as disclosed herein includes (1) a plurality of magnets arranged and oriented relative to adjacent ones of the magnets to form a substantially cylindrical Halbach array the combined magnetic field of which is concentrated on one side of the array, wherein the substantially cylindrical Halbach array has a rotational axis and each of at least a subset of the magnets is oriented in a fixed position such that the longitudinal axis of the magnet is at a prescribed skew angle to the rotational axis; and (2) a retaining structure adjacent to at least a subset of the magnets comprising the plurality of magnets and configured to hold one or more of said subset of magnets in place.

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: 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: A first measurement of a magnet that rotates is received from a first set of Hall sensors in a first component. A second measurement is received from a second set of Hall sensors in a second component where the first component and the second component are in a plane that is parallel to an axis of rotation associated with the magnet. An angle associated with the magnet is determined based at least in part on the first measurement and the second measurement.

Abstract: A first measurement of a magnet that rotates is received from a first set of Hall sensors in a first component. A second measurement is received from a second set of Hall sensors in a second component where the first component and the second component are in a plane that is parallel to an axis of rotation associated with the magnet. An angle associated with the magnet is determined based at least in part on the first measurement and the second measurement.

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 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: 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.