IP Library › Granted Patent US 12693047
Granted Patent B2
US 12693047 · App. 18/165,456 · Granted Jul 28, 2026

Motor integrated auxiliary bearings for aircraft machines

Inventors: Viktor Kilchyk (Lancaster, NY); Brent J. Merritt (Southwick, MA)
Assignee: HAMILTON SUNDSTRAND CORPORATION
F25B9/004B64D13/06B64D2013/0618B64D2013/0648
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Quick Facts
Patent No.
US 12693047
App. No.
18/165,456
Granted
Jul 28, 2026
Kind
B2
Abstract

Aircraft air cycle machines include a housing defining a motor cavity, a shaft arranged within the housing, a turbine operably coupled to the shaft and arranged within the housing, a compressor operably coupled to the shaft and arranged within the housing, and a motor arranged within the motor cavity, wherein the motor comprises a motor stator assembly fixedly connected to the housing and a motor rotor assembly rotationally coupled to the shaft.

Claims (38)

1 . An aircraft air cycle machine comprising:

a housing defining a motor cavity;

a shaft arranged within the housing;

a turbine operably coupled to the shaft and arranged within the housing;

a compressor operably coupled to the shaft and arranged within the housing;

an axial flux motor arranged within the motor cavity, wherein the motor comprises a motor stator assembly fixedly connected to the housing and a motor rotor assembly rotationally coupled to the shaft; and

a motor controller configured to direct electrical power into the motor stator assembly to generate a magnetic field, wherein the motor controller is configured to operate in a bearing mode of operation wherein the motor rotor assembly is rotationally decoupled from the shaft, and the interaction of the motor rotor assembly and the motor stator assembly provides a magnetic thrust bearing functionality to the shaft.

2 . The aircraft air cycle machine of claim 1 , further comprising a clutch assembly arranged between the motor rotor assembly and the shaft, wherein the clutch assembly is operable to rotationally couple and decouple the motor rotor assembly with the shaft.

3 . The aircraft air cycle machine of claim 1 , further comprising at least one mounting structure arranged to fixedly mount the motor stator assembly to the housing.

4 . The aircraft air cycle machine of claim 1 , wherein the motor controller is configured to operate in a power input mode of operation to input rotational energy into the shaft.

5 . The aircraft air cycle machine of claim 1 , wherein the motor controller is configured to operate in a power output mode of operation to extract energy from the shaft.

6 . The aircraft air cycle machine of claim 1 , further comprising at least one mechanical bearing arranged on the shaft.

7 . The aircraft air cycle machine of claim 6 , wherein the at least one mechanical bearing comprises at least one journal bearing.

8 . The aircraft air cycle machine of claim 6 , wherein the at least one mechanical bearing comprises at least one thrust bearing.

9 . The aircraft air cycle machine of claim 6 , wherein the at least one mechanical bearing comprises at least one journal bearing and at least one thrust bearing.

10 . Aircraft air cycle machine of claim 1 , wherein, in the bearing mode of operation, the motor rotor assembly is disconnected from the shaft.

11 . An aircraft environmental control system comprising:

at least one ram air fan system; and

an air cycle machine comprising:

a housing defining a motor cavity;

a shaft arranged within the housing;

a turbine operably coupled to the shaft and arranged within the housing;

a compressor operably coupled to the shaft and arranged within the housing;

an axial flux motor arranged within the motor cavity, wherein the motor comprises a motor stator assembly fixedly connected to the housing and a motor rotor assembly rotationally coupled to the shaft; and

a motor controller configured to direct electrical power into the motor stator assembly to generate a magnetic field, wherein the motor controller is configured to operate in a bearing mode of operation wherein the motor rotor assembly is rotationally decoupled from the shaft, and the interaction of the motor rotor assembly and the motor stator assembly provides a magnetic thrust bearing functionality to the shaft.

12 . The aircraft environmental control system of claim 11 , wherein the motor controller is configured to operate in a power input mode of operation to input rotational energy into the shaft.

13 . The aircraft environmental control system of claim 11 , wherein the motor controller is configured to operate in a power output mode of operation to extract energy from the shaft.

14 . The aircraft environmental control system of claim 11 , wherein, in the bearing mode of operation, the motor rotor assembly is disconnected from the shaft.

15 . A method of operating an air cycle machine onboard an aircraft, the air cycle machine comprising a housing, a shaft, and an axial flux motor comprising a motor stator assembly fixedly connected to the housing and a motor rotor assembly rotationally coupled to the shaft, and a motor controller configured to direct electrical power into the motor stator assembly to generate a magnetic field, the method comprising:

selectively operating the motor, using the motor controller, in a power input mode of operation or a bearing mode of operation, wherein:

in the power input mode of operation, the motor rotor assembly is rotationally coupled to the shaft and configured to input rotational energy into the shaft; and

in the bearing mode of operation, the motor rotor assembly is rotationally decoupled from the shaft, and the interaction of the motor rotor assembly and the motor stator assembly provides a magnetic thrust bearing functionality to the shaft.

16 . The method of claim 15 , wherein the air cycle machine further comprises a clutch assembly arranged between the motor rotor assembly and the shaft, the method further comprising:

selectively operating the clutch assembly to rotationally couple and decouple the motor rotor assembly with the shaft.

17 . The method of claim 15 , further comprising fixedly mounting the motor stator assembly to the housing using at least one mounting structure.

18 . The method of claim 15 , further comprising operating the motor controller in a power input mode of operation to input rotational energy into the shaft.

19 . The method of claim 15 , further comprising operating the motor controller in a power output mode of operation to extract energy from the shaft.

20 . The method of claim 15 , wherein, in the bearing mode of operation, the motor rotor assembly is disconnected from the shaft.