Abstract: Embodiments of the present disclosure provide systems and methods for averting, shedding, or otherwise managing ice accretions that may develop during flight of an aircraft. Example systems and methods generate heat at targeted areas of a propeller assembly by electric heating systems that utilize propeller motion.

Abstract: A method for manufacturing a rotor assembly of an electric engine, comprising: loading a first and second plurality of magnets in a magnet insertion tool, loading a sleeve in the magnet insertion tool: performing an insertion movement of the first plurality of magnets with respect to the second plurality of magnets using the magnet insertion tool, wherein the insertion movement comprises: moving the first plurality of magnets in a radial direction of the sleeve; moving the second plurality of magnets in an axial direction of the sleeve; and expanding a radius of the sleeve in the radial direction using the magnet insertion tool during the insertion movement.

Abstract: A VTOL aircraft includes a lift propeller configured to provide lift during takeoff, landing and hover operations. The lift propeller is configured to be stowed close to a boom surface when not in use during, e.g., cruise flight, to minimize drag around propeller surfaces. The lift propeller may be displaced vertically with respect to the boom when switching to a lift configuration to provide greater separation from the boom to improve lift efficiency and reduce unwanted vibrations. The lift propeller may have a fail-safe configuration that allows the propeller to move passively between lift and stowed configurations, and to fully rotate even when fully retracted.

Abstract: An electric propulsion system comprising an electric motor assembly. The electric motor assembly may include a housing having an internal volume, a stator ring disposed about a perimeter of the internal volume, and a rotor positioned within the stator. The electric motor assembly may include a main shaft connected to the rotor via a gear reduction, wherein the main shaft extends through the rotor. The electric motor assembly may include a collar connected to the main shaft, wherein the collar encircles the main shaft, and at least a portion of the collar is configured to direct a fluid away from the main shaft and toward the stator ring.

Abstract: A motor assembly for a propulsion system, the motor assembly including a motor housing; a rotor; a power inverter; a main shaft; wherein the main shaft extends through the rotor; and a fluid distribution system including a fluid reservoir; a pump configured to distribute a fluid to a component of the motor assembly; and a filter having a circumferential side, wherein the filter is configured to filter the fluid through the circumferential side, wherein the filter is located adjacent to the main shaft.

Abstract: An electric propulsion system for a vertical take-off and landing (VTOL) aircraft having a heat exchanger to cool fluids used in an electrical engine, the electric propulsion system comprising at least one electrical engine mechanically connected directly or indirectly to a fuselage of the VTOL aircraft and electrically connected to an electrical power source. The electrical engine may comprise an electrical motor having a stator and a rotor; a gearbox assembly comprising a sun gear; at least one planetary gear; a ring gear; and a planetary carrier. The electric engine may include an inverter assembly comprising a thermal plate and an inverter assembly housing; an end bell assembly that is connected to the thermal plate of the inverter assembly; and a heat exchanger comprising an array of cooling fins and tubes.

Abstract: An electric propulsion system for a vertical takeoff-and-landing aircraft having an inverter assembly, a gearbox assembly, an electric motor assembly. The inverter assembly, the gearbox assembly, and the electric motor assembly may be substantially aligned along an axis. The inverter assembly, a gearbox assembly, and electric motor assembly may each abut at least one of the others. The electric engine may use a liquid, such as oil, for cooling and lubricating components of the inverter assembly, gearbox assembly, and electric motor assembly. Further, the electric engine may use volumes of oil for cooling and lubricating components below a threshold volume so that the electric engines do not require a fire protective barrier.

Abstract: Embodiments of the present disclosure provide systems and methods for averting, shedding, or otherwise managing ice accretions that may develop during flight of an aircraft. Example systems and methods direct oil from a lubrication and cooling path to targeted sections of ice-prone surfaces to manage ice accretion in a way that does not unduly increase the total volume of oil, require larger pumps, or complicate the system.

Abstract: An electric propulsion system for a vertical take-off and landing (VTOL) aircraft having a heat exchanger to cool fluids used in an electrical engine, the electric propulsion system comprising at least one electrical engine mechanically connected directly or indirectly to a fuselage of the VTOL aircraft and electrically connected to an electrical power source. The electrical engine may comprise an electrical motor having a stator and a rotor; a gearbox assembly comprising a sun gear; at least one planetary gear; a ring gear; and a planetary carrier. The electric engine may include an inverter assembly comprising a thermal plate and an inverter assembly housing; an end bell assembly that is connected to the thermal plate of the inverter assembly; and a heat exchanger comprising an array of cooling fins and tubes.

Abstract: An electric propulsion system for a vertical take-off and landing (VTOL) aircraft, the electric propulsion system including an electrical motor having a stator and a rotor. The electric propulsion system may include a main shaft possessing at least one shoulder on an outer surface of the main shaft. The electric propulsion system may include a gearbox assembly comprising a sun gear that is concentrically aligned with the main shaft at least one planetary gear that interfaces with the sun gear. The electric propulsion system may include a planetary carrier, wherein a center of the planetary carrier is concentrically aligned with the main shaft. The electric propulsion system may include a propeller flange assembly that travels through the rotor, and an axial buttress positioned in the at least one shoulder located on the main shaft.

Abstract: An inverter assembly for an electrical propulsion system comprises at least one printed circuit board assembly (PCBA) having a plurality of power modules, a thermal plate comprising one or more channels, a plurality of fin arrays thermally coupled to the plurality of power modules, and a housing. The plurality of fin arrays are configured to receive a fluid from the one or more channels. The at least one printed circuit board assembly and the thermal plate are disposed within the housing.

Abstract: Embodiments of the present disclosure provide systems and methods for averting, shedding, or otherwise managing ice accretions that may develop during flight of an aircraft. Example systems and methods direct oil from a lubrication and cooling path to targeted sections of ice-prone surfaces to manage ice accretion in a way that does not unduly increase the total volume of oil, require larger pumps, or complicate the system.

Abstract: Embodiments of the present disclosure provide systems and methods for averting, shedding, or otherwise managing ice accretions that may develop during flight of an aircraft. Example systems and methods generate heat at targeted areas of a propeller assembly by electric heating systems that utilize propeller motion.

Abstract: A motor gearbox assembly includes a gearbox housing that encloses a motor comprising a stator and a rotor, which is rotatable with respect to the stator. The rotor is rotatably mounted on a main power output shaft and is coupled to a first rotor pinion gear. The assembly further comprises a layshaft rotatably mounted in the gearbox housing outside of the motor, a first layshaft gear at a first axial end of the layshaft on a first side of the rotor and the stator, the first layshaft gear being engaged with the first rotor pinion gear and a second layshaft gear at a second axial end of the layshaft, the second axial end being on a second side of the rotor and the stator that is opposite the first side, the second layshaft gear being engaged with a power output gear coupled to the main power output shaft.

Abstract: A rotor assembly has a sleeve, a rotor hub, a lamination core, and a plurality of tapered magnets disposed circumferentially around an inner diameter of the sleeve. The plurality of tapered magnets are configured to abut on one another. The plurality of tapered magnets includes a first set of tapered magnets and a second set of tapered magnets. Insertion of the first set of tapered magnets axially relative to the second set of tapered magnets is configured to increase a diameter of the sleeve. The rotor hub is configured to retain at least one of the lamination core, the plurality of tapered magnets, or the sleeve.

Abstract: A method for balancing a rotor of an electric engine, comprising: identifying an axis of rotation of the rotor, determining an imbalance present in the rotor by rotating the rotor about the axis of rotation, wherein determining the imbalance includes rotating the rotor and detecting an amplitude of the imbalance. The method further comprising: calculating an amount of mass to remove at a position along an inner circumference of the rotor such that a center of mass of the rotor coincides with the axis of rotation of the rotor and removing the amount of mass from the inner circumference of the rotor.

Abstract: A propulsion system, comprising: a motor assembly including a stator and a rotor, a heat exchanger configured to receive air to cool a liquid, and a thermal plate including one or more channels configured to convey the liquid from the heat exchanger to the motor assembly. The heat exchanger is mechanically and fluidically coupled to the thermal plate.

Abstract: An electrical propulsion system comprises an inverter, an electrical motor assembly, an assembly, and a rotor position sensor. The inverter comprises a printed circuit board assembly (PCBA). The electrical motor assembly comprises a stator and a rotor. The assembly is configured to rotate a propeller and comprises a moving component and a stationary component. The rotor position sensor comprises at least one sensor coupled to the PCBA, and a magnet located on the moving component. The at least one sensor is configured to detect a magnetic field of the magnet through the stationary component.

Abstract: A method for manufacturing a rotor assembly of an electric engine, comprising: loading a first and second plurality of magnets in a magnet insertion tool, loading a sleeve in the magnet insertion tool, performing a first insertion movement using the magnet insertion tool, wherein the first insertion movement comprises moving one of the first plurality of magnets or the second plurality of magnets in a radial direction of the sleeve, and performing a second insertion movement using the magnet insertion tool, wherein the second insertion movement comprises moving one of the first plurality of magnets or the second plurality of magnets with respect to the sleeve in an axial direction of the sleeve. The radius of the sleeve is expanded in a radial direction during one of the first insertion movement or the second insertion movement.

Abstract: A tilt apparatus of an aircraft, comprising: a first frame, a second frame moveably coupled to the first frame, a propulsion system coupled to the second frame and configured to move with the second frame, the propulsion system comprising: a propeller, a motor configured to rotate the propeller, and a propulsion inverter configured to supply current to the motor. The tilt apparatus further comprises a tilt actuation system coupled to the second frame and configured to tilt with the second frame with respect to the first frame, the tilt actuation system comprising: a tilt actuator; a tilt actuator inverter configured to supply current to the tilt actuator, and a tilt actuator gearbox coupled to the second frame and configured to tilt with the second frame. The tilt actuator is configured to the tilt the second frame with respect to the first frame via the tilt actuator gearbox.