Electric propulsion system for delivering high torque
A system to convert electrical power to torque is disclosed where the system includes one or more motor controllers, each motor controller adapted and configured to receive power input commands and to receive high-voltage, direct-current (HVDC) input power and convert the HVDC input power to multiphase high-voltage, alternating-current (HVAC) output power, wherein each motor controller varies its respective multiphase HVAC output power in response to the power input commands received; and an electric motor assembly having a main shaft for supplying torque, the electric motor configured and adapted to receive input power as multiphase HVAC from the one or more motor controllers to rotate the main shaft. The system in an embodiment is configured as a propulsion system, wherein the shaft of the electric motor assembly is configured to supply torque to a propulsor of an aircraft.
1. A system to convert electrical power to torque configured as a propulsion system, the system comprising:
at least two motor controllers, each motor controller adapted and configured to receive power input commands and to receive direct-current (DC) input power and convert the DC input power to multiphase alternating-current (AC) output power, wherein each motor controller varies its respective multiphase AC output power in response to the power input commands received and each of the at least two motor controllers has a housing;
an electric motor assembly having a main shaft for supplying torque to a propulsor element of an aircraft, the electric motor configured and adapted to receive input power as multiphase AC from the at least two motor controllers to rotate the main shaft, wherein the electric motor assembly comprises one or more stator modules, each stator module having a plurality of stator windings configured to receive the AC output power from the at least two motor controllers;
a governor interface assembly to adjust the pitch of the propulsor element, wherein the governor interface derives a speed reference of the propulsor element from the main shaft of the electric motor assembly and utilizes hydraulic fluid to adjust the pitch of the propulsor element; and
a liquid cooling system having a liquid coolant, wherein the liquid cooling system is configured to direct the liquid coolant to flow through the plurality of stator windings in at least one of the one or more stator modules to cool the plurality of stator windings in the at least one of the one or more stator modules and so that the same liquid coolant that flows through the plurality of stator windings flows through the housing of the at least two motor controllers in parallel to cool the at least two motor controllers and through the electric motor assembly in series with the at least two motor controllers, and wherein the hydraulic fluid used to adjust the pitch of the propulsor element is the same fluid used in the cooling system.
2. The system of claim 1 , wherein the electric motor assembly comprises:
one or more rotor assemblies, each rotor assembly having a plurality of magnets arranged around the outer periphery of a hub, wherein at least one of the one or more rotor assemblies is configured to rotate the main shaft, and at least one or more of the rotor assemblies is associated with, concentrically contained within, and rotatable relative to one of the one or more stator modules.
3. The system of claim 1 , wherein the liquid cooling system contains one or more temperature sensors and data from the temperature sensors is communicated to one or more of the at least two motor controllers for processing.
4. The system of claim 1 , wherein the liquid cooling system contains one or more pressure sensors and data from the pressure sensors is communicated to one or more of the at least two motor controllers for processing.
5. The system of claim 1 , wherein the cooling system further contains a reservoir to contain the liquid coolant, a conduit system to channel the liquid coolant at least between the at least two motor controllers and the electric motor assembly, and at least one pump to pump the liquid coolant.
6. The system of claim 5 , further comprising an integrated accessory gearbox assembly that derives power from the electric motor assembly, wherein the integrated accessory gearbox is configured to power the pump.
7. The system of claim 2 , wherein each one of the at least two motor controllers is are configured to produce and supply two independent multi-phases of AC output power and each stator module in the electric motor assembly is configured to receive at least two independent multiphases of AC output power from at least one of the at least two motor controllers.
8. The system of claim 7 , wherein a single motor controller having a single housing with a single cooling channel to receive liquid coolant produces and supplies the two independent multi-phases of AC output power, wherein the single motor controller contains two independent circuits, each to produce one of the independent multiphase AC outputs.
9. The system of claim 1 , wherein the electric motor assembly is configured to receive fluid as a lubricant to lubricate one or more moving parts within the electric motor assembly, wherein the same fluid used as lubricant in the electric motor assembly is used as coolant in the cooling system.
10. The system of claim 1 , further comprising an integrated accessory gearbox assembly that derives power from the electric motor assembly, wherein the integrated accessory gearbox is configured to receive fluid as a lubricant to lubricate one or more moving parts within the accessory gearbox assembly, wherein the same fluid used as a lubricant in the integrated gearbox assembly is used as coolant in the cooling system.
11. The system of claim 1 , further comprising an integrated gearbox assembly that derives power from the electric motor assembly, wherein the integrated gearbox is configured to receive lubricant fluid to lubricate one or more moving parts within the gearbox assembly, and wherein the electric motor assembly is configured to receive the lubricant to lubricate one or more moving parts within the electric motor assembly, and the lubricant fluid, the hydraulic fluid, and the liquid coolant are all the same fluid taken from a common reservoir.
12. The system of claim 1 , wherein the at least two motor controllers communicate over a bus, and the system is capable of operating if one of the at least two motor controllers is degraded, faulty, or inoperable.
13. The system of claim 1 , further comprising one or more system controllers for receiving control input and outputting power input commands to at least one of the at least two motor controllers.
14. The system of claim 1 , wherein at least one of the at least two motor controllers has at least two digital Controller Area Network communication interfaces to receive power input commands, wherein at least one the digital Controller Area Network communication interfaces is redundant.
15. The system of claim 1 wherein at least one of the at least two motor controllers receives temperature data from the electric motor assembly.
16. The system of claim 1 , wherein the motor controller receives information on the main shaft of the electric motor assembly including at least one of the group consisting of speed, angular position, and combinations thereof.
17. The system of claim 1 , wherein at least one of the at least two motor controllers are configured to received direct current input power of between 400-800 volts.
18. The system of claim 1 , wherein the liquid coolant is configured to flow through the plurality of stator windings and to flow serially through the at least two motor controllers.
19. The system of claim 18 , further comprising a motor lubricant fluid to lubricate one or more moving parts within the electric motor assembly, wherein the same motor lubricant fluid within the electric motor assembly is the same coolant fluid that flows through and in contact with the plurality of stator windings.