Carbon fiber motor rotor integrating propeller mount
A rotor for use with an airborne wind turbine, wherein the rotor comprises a front flange, a can, a rear flange, and a rigid insert comprising a propeller mount, wherein the front flange, can, and rear flange comprise one of carbon fiber and spun aluminum, wherein a rear end of the front flange is attached to a front end of the can, and the rear flange is mounted to a rear end of the can, wherein the rigid insert is bonded to the front flange; and wherein the rigid insert comprises a tube that axially extends within the rotor to allow for the positioning of a driveshaft therethrough.
1. An airborne wind turbine system, comprising:
an aerial vehicle having a main wing;
an electrically conductive tether having a first end secured to the main wing of the aerial vehicle and a second end secured to a ground station;
a plurality of power generating turbines connected to the main wing wherein at least one of the power generating turbines are operable in a power generation mode and in a thrust generation mode, and includes a propeller mounted to a rotor;
wherein the rotor comprises:
a front flange;
a can;
a rear flange; and
a rigid insert comprising a propeller mount;
wherein the front flange, can, and rear flange comprise one of carbon fiber and spun aluminum;
wherein a rear end of the front flange is attached to a front end of the can, and the rear flange is mounted to a rear end of the can;
wherein the rigid insert is bonded to the front flange;
wherein the rigid insert comprises a tube that axially extends within the rotor to allow for the positioning of a driveshaft therethrough; and
wherein the rotor has a front surface that is attached to a root of the propeller.
2. The airborne wind turbine system of claim 1 , wherein a front surface of the front flange is shaped to conform to a shape of a rear surface of the root of the propeller.
3. The airborne wind turbine system of claim 1 , wherein the rigid insert includes a nut plate for attachment to the root of the propeller.
4. The airborne wind turbine system of claim 3 , wherein the front surface of the front flange includes divots around bolt holes in the nut plate to provide an out-of-plane shape to the front surface of the front flange.
5. The airborne wind turbine system of claim 4 , wherein the tube is tapered downwardly as it extends towards the rear flange.
6. The airborne wind turbine system of claim 1 , wherein a locating flange extends rearwardly from the rear flange for sealing engagement with a stator positioned on the main wing.
7. The airborne wind turbine system of claim 1 , wherein the rigid insert comprises a metal.
8. The airborne wind turbine system of claim 1 , wherein the rigid insert comprises carbon fiber.
9. The airborne wind turbine system of claim 1 , wherein the front flange is mounted to the front end of the can by bonding to a middle flange extending forwardly from the front end of the can.
10. The airborne wind turbine system of claim 1 , wherein the front flange has a conical shape as it tapers outwardly from a front surface of the front flange to a rear surface of the front flange.
11. The airborne wind turbine system of claim 5 , wherein the driveshaft is bonded to or press fit to an inner surface of the can.
12. The airborne wind turbine system of claim 10 , wherein the can has a cylindrical outer surface.
13. A rotor for use with an airborne wind turbine system wherein the rotor comprises:
a front flange;
a can;
a rear flange; and
a rigid insert comprising a propeller mount;
wherein the front flange, can, and rear flange comprise one of carbon fiber and spun aluminum;
wherein a rear end of the front flange is attached to a front end of the can, and the rear flange is mounted to a rear end of the can;
wherein the rigid insert is bonded to the front flange;
wherein the rigid insert comprises a tube that axially extends within the rotor to allow for the positioning of a driveshaft therethrough; and
wherein the rotor has a front surface that is adapted for attachment to a root of a propeller.
14. The rotor of claim 13 , wherein a front surface of the front flange is shaped to conform to a shape of a rear surface of the root of the propeller.
15. The rotor of claim 13 , wherein the rigid insert includes a nut plate for attachment to the root of the propeller.
16. The rotor of claim 15 , wherein the front surface of the front flange includes divots around bolt holes in the nut plate to provide an out-of-plane shape to the front surface of the front flange.
17. The rotor of claim 13 , wherein the rotor is adapted to receive a driveshaft that is tapered downwardly towards the rear flange.
18. The rotor of claim 13 , wherein a locating flange extends rearwardly from the rear flange for sealing engagement with a stator positioned on a main wing.
19. The rotor of claim 13 , wherein the rigid insert comprises carbon fiber.
20. The rotor of claim 13 , wherein the front flange is mounted to the front end of the can by bonding to a middle flange extending forwardly from the front end of the can.
21. The rotor of claim 13 , wherein the front flange has a conical shape as it tapers outwardly from a front surface of the front flange to a rear surface of the front flange.