Lightweight Direct-Drive Electric Propulsion Motor

The heavy lift drone delivery industry is rapidly expanding and is a perfect commercialization path for lightweight electric motor technology. The industry is looking to create new air transport services based on cost effective hybrid/electric propulsion technologies. The combination of high-performance engine, battery, electric motor, flight control software and ride-hailing technologies are all coming together, being mixed and matched by different startup companies in an exciting new space. Two key aircraft parameters, safety and range, must be improved in order for these emergent technologies to achieve their potential and gain the publicÆs trust in this new domain of aviation. The electric motor is a safety critical component and it is imperative that propulsion motors be extremely reliable. The proposed innovation augments ToyonÆs recently developed, highly power-dense direct-drive electric motor with liquid cooling for the motor and power electronics. By tightly integrating the electric motor, power electronics and cooling, a very lightweight and compact propulsion motor can be built which significantly improves both power density and reliability. Highly effective cooling both increases power density but also keeps winding temperatures low which are a key source of motor failures.