An electrical propulsion system includes an electrical motor configured to drive one or more propellers of the aircraft, a capacitor configured to stabilize a direct current (DC) bus voltage, a first inverter circuit coupled to the capacitor and configured to convert the DC bus voltage to alternate current (AC) voltages to drive a first set of stator windings of the electrical motor, in response to a first pulse width modulation (PWM) vector, and a second inverter circuit coupled to the capacitor and configured to convert the DC bus voltage to AC voltages to drive a second set of stator windings of the electrical motor, in response to a second PWM vector. The first PWM vector and the second PWM vector are substantially equal and opposite vectors.

An electrical propulsion system includes an electrical motor configured to drive one or more propellers of the aircraft, a capacitor configured to stabilize a direct current (DC) bus voltage, a first inverter circuit coupled to the capacitor and configured to convert the DC bus voltage to alternate current (AC) voltages to drive a first set of stator windings of the electrical motor, in response to a first pulse width modulation (PWM) vector, and a second inverter circuit coupled to the capacitor and configured to convert the DC bus voltage to AC voltages to drive a second set of stator windings of the electrical motor, in response to a second PWM vector. The first PWM vector and the second PWM vector are substantially equal and opposite vectors.

An inverter assembly for an electrical propulsion system comprises at least one printed circuit board assembly (PCBA) having a plurality of power modules, a thermal plate comprising one or more channels, a plurality of fin arrays thermally coupled to the plurality of power modules, and a housing. The plurality of fin arrays are configured to receive a fluid from the one or more channels. The at least one printed circuit board assembly and the thermal plate are disposed within the housing.

An electrical propulsion system includes an electrical motor configured to drive one or more propellers of the aircraft, a capacitor configured to stabilize a direct current (DC) bus voltage, a first inverter circuit coupled to the capacitor and configured to convert the DC bus voltage to alternate current (AC) voltages to drive a first set of stator windings of the electrical motor, in response to a first pulse width modulation (PWM) vector, and a second inverter circuit coupled to the capacitor and configured to convert the DC bus voltage to AC voltages to drive a second set of stator windings of the electrical motor, in response to a second PWM vector. The first PWM vector and the second PWM vector are substantially equal and opposite vectors.

A electrical power system comprises: an electrical machine operable to output AC; a DC electrical network; a power electronics converter connected between the AC output of the electrical machine and the DC electrical network and including a plurality of transistors and associated diodes connected in parallel with the transistors; and a controller configured to control switching of the transistors of the converter so that, during normal operation of the electrical power system, the converter rectifies the AC output of the electrical machine to supply the DC electrical network with DC electrical power. The controller is further configured, responsive to a determination to the effect there is a fault in the DC electrical network, to control a voltage source, to inject a voltage to bias the diodes of the converter, and to control the switching of the transistors to control a level of current supplied to the faulted DC electrical network.

A electrical power system comprises: an electrical machine operable to output AC; a DC electrical network; a power electronics converter connected between the AC output of the electrical machine and the DC electrical network and including a plurality of transistors and associated diodes connected in parallel with the transistors; and a controller configured to control switching of the transistors of the converter so that, during normal operation of the electrical power system, the converter rectifies the AC output of the electrical machine to supply the DC electrical network with DC electrical power. The controller is further configured, responsive to a determination to the effect there is a fault in the DC electrical network, to control a voltage source, to inject a voltage to bias the diodes of the converter, and to control the switching of the transistors to control a level of current supplied to the faulted DC electrical network.

A method of designing and manufacturing a power electronics converter for an electrical power system is provided. A circuit design for the power electronics converter is selected. A shape constraint for integrating the power electronics converter into the electrical power system is determined, and at least one multi-layer carrier substrate is obtained according to the determined shape constraint. A plurality of power semiconductor prepackages are obtained. Each power semiconductor prepackage includes a power semiconductor switching element embedded in a solid insulating material and an electrical connection extending through the solid insulating material from a terminal of the power semiconductor switching element to a connection surface of the prepackage. The power electronics converter is assembled by forming electrically conductive connections in a z-direction connecting terminals of the power semiconductor switching elements of the power semiconductor prepackages and one or more electrically conductive layers of the multi-layer carrier substrate.

A method of designing and manufacturing a power electronics converter for an electrical power system is provided. A circuit design for the power electronics converter is selected. A shape constraint for integrating the power electronics converter into the electrical power system is determined, and at least one multi-layer carrier substrate is obtained according to the determined shape constraint. A plurality of power semiconductor prepackages are obtained. Each power semiconductor prepackage includes a power semiconductor switching element embedded in a solid insulating material and an electrical connection extending through the solid insulating material from a terminal of the power semiconductor switching element to a connection surface of the prepackage. The power electronics converter is assembled by forming electrically conductive connections in a z-direction connecting terminals of the power semiconductor switching elements of the power semiconductor prepackages and one or more electrically conductive layers of the multi-layer carrier substrate.

An electric propulsion system for a vertical take-off and landing (VTOL) aircraft, the electric propulsion system including an electrical motor having a stator and a rotor. The electric propulsion system may include a main shaft possessing at least one shoulder on an outer surface of the main shaft. The electric propulsion system may include a gearbox assembly comprising a sun gear that is concentrically aligned with the main shaft at least one planetary gear that interfaces with the sun gear. The electric propulsion system may include a planetary carrier, wherein a center of the planetary carrier is concentrically aligned with the main shaft. The electric propulsion system may include a propeller flange assembly that travels through the rotor, and an axial buttress positioned in the at least one shoulder located on the main shaft.

An electric propulsion system for a vertical take-off and landing (VTOL) aircraft, the electric propulsion system including an electrical motor having a stator and a rotor. The electric propulsion system may include a main shaft possessing at least one shoulder on an outer surface of the main shaft. The electric propulsion system may include a gearbox assembly comprising a sun gear that is concentrically aligned with the main shaft at least one planetary gear that interfaces with the sun gear. The electric propulsion system may include a planetary carrier, wherein a center of the planetary carrier is concentrically aligned with the main shaft. The electric propulsion system may include a propeller flange assembly that travels through the rotor, and an axial buttress positioned in the at least one shoulder located on the main shaft.