Systems, methods, and mechanical designs for inverters for eVTOL aircraft
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.
1. An electrical propulsion system, comprising:
an inverter comprising a printed circuit board assembly (PCBA);
an electrical motor assembly comprising a stator and a rotor;
an assembly configured to rotate a propeller comprising a moving component and a stationary component; and
a rotor position sensor comprising:
at least one sensor coupled to the PCBA, and
a magnet located on the moving component, wherein the at least one sensor is configured to detect a magnetic field of the magnet through the stationary component.
2. The electrical propulsion system of claim 1 , wherein the PCBA further comprises an integrated oil temperature sensor.
3. The electrical propulsion system of claim 2 , wherein the integrated oil temperature sensor is positioned to sense temperature of cooling oil.
4. The electrical propulsion system of claim 3 , wherein the cooling oil is configured to cool at least one of a MOSFET or a power module.
5. The electrical propulsion system of claim 1 , further comprising a secondary speed sensor.
6. The electrical propulsion system of claim 5 , wherein the secondary speed sensor is connected to a control board of the electrical propulsion system.
7. The electrical propulsion system of claim 1 , wherein the moving component is a gear, and wherein the magnet is located on the gear.
8. The electrical propulsion system of claim 7 , wherein the gear is configured to transfer torque from the electrical motor assembly to the propeller.
9. The electrical propulsion system of claim 7 , wherein the gear is a planetary carrier.
10. The electrical propulsion system of claim 1 , wherein the stationary component comprises at least one of: a thermal plate or end bell plate.
11. An aircraft, comprising:
a boom;
at least one electrical propulsion system mounted to the boom, comprising:
a propeller;
an inverter comprising a printed circuit board assembly (PCBA);
an electrical motor assembly comprising a stator and a rotor;
an assembly configured to rotate the propeller comprising a moving component and a stationary component; and
a rotor position sensor comprising:
at least one sensor coupled to the PCBA, and
a magnet located on the moving component, wherein the at least one sensor is configured to detect a magnetic field of the magnet through the stationary component.
12. The aircraft of claim 11 , wherein the aircraft is a vertical take-off and landing (VTOL) aircraft.
13. The aircraft of claim 11 , wherein the PCBA further comprises an integrated oil temperature sensor.
14. The aircraft of claim 13 , wherein the integrated oil temperature sensor is positioned to sense temperature of cooling oil.
15. The aircraft of claim 14 , wherein the cooling oil is configured to cool at least one of a MOSFET or a power module.
16. The aircraft of claim 11 , further comprising a secondary speed sensor.
17. The aircraft of claim 16 , wherein the secondary speed sensor is connected to a control board of the electrical propulsion system.
18. The aircraft of claim 11 , wherein the moving component is a gear, and wherein the magnet is located on the gear.
19. The aircraft of claim 18 , wherein the gear is configured to transfer torque from the electrical motor assembly to the propeller.
20. The aircraft of claim 18 , wherein the gear is a planetary carrier.
21. The aircraft of claim 11 , wherein the stationary component comprises at least one of: a thermal plate or end bell plate.
22. A method of operating an electrical propulsion system, the method comprising:
operating an electrical motor assembly, the electrical motor assembly comprising at least a stator and a rotor;
providing electrical power to the electrical motor assembly by an inverter, the inverter comprising a printed circuit board assembly (PCBA);
operating an assembly to rotate a propeller, the assembly comprising a moving component and a stationary component; and
sensing a rotational position of the propeller using a rotor position sensor comprising:
at least one sensor integrated to the PCBA; and
a magnet located on the moving component, wherein sensing the rotational position of the propeller comprises using the at least one sensor to detect a magnetic field of the magnet through the stationary component to sense a position of the magnet.
23. The method of claim 22 , wherein the PCBA further comprises an integrated oil temperature sensor, and sensing a temperature by the integrated oil temperature sensor.
24. The method of claim 23 , further comprising sensing a temperature of cooling oil.
25. The method of claim 24 , further comprising cooling, by the cooling oil, at least one of a MOSFET or a power module.
26. The method of claim 22 , further comprising sensing a speed of the electric propulsion system by a secondary speed sensor connected to a control board of the electrical propulsion system.
27. The method of claim 22 , wherein the moving component is a gear, and wherein the magnet is located on the gear.
28. The method of claim 27 , wherein the gear is configured to transfer torque from the electrical motor assembly to the propeller.
29. The method of claim 27 , wherein the gear is a planetary carrier.
30. The method of claim 22 , wherein the stationary component comprises at least one of: a thermal plate or end bell plate.