Submersible electric thruster

• US 9,963,212 B2
• Filed: 04/29/2015
• Issued: 05/08/2018
• Est. Priority Date: 05/01/2014
• Status: Active Grant

• Current Assignee: Blue Robotics Inc.
• Original Assignee: Blue Robotics Inc.
• Inventors: Jehangir, Rustom Friedrich, Spadola, Joseph Anthony
• Primary Examiner(s): Bertheaud, Peter J
• Assistant Examiner(s): Kasture, Dnyanesh
• Application Number:
  US14/699,478
• Publication Number:
  US 20150314849A1
• Time in Patent Office: 1,105 Days
• CPC Class Codes: B63H 1/20 Hubs; Blade connections
• CPC Class Codes: B63H 2005/1258 with electric power transmission to propellers, i.e. with integrated electric propeller motors
• CPC Class Codes: B63H 2021/216 using electric control means
• CPC Class Codes: B63H 21/17 by electric motor
• CPC Class Codes: B63H 21/21 Control means for engine or transmission, specially adapted for use on marine vessels
• CPC Class Codes: B63H 21/24 the vessels being small craft, e.g. racing boats
• CPC Class Codes: B63H 23/24 electric dynamo-electric machines H02K
• CPC Class Codes: B63H 5/14 characterised by being mounted in non-rotating ducts or rings, e.g. adjustable for steering purpose shrouding ring attached to blades B63H1/16; jet propulsion B63H11/00
• CPC Class Codes: B63H 5/15 Nozzles, e.g. Kort-type
• CPC Class Codes: H02K 1/17 Stator cores with permanent magnets
• CPC Class Codes: H02K 1/187 to inner stators
• CPC Class Codes: H02K 11/33 Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 5/04 Casings or enclosures characterised by the shape, form or construction thereof
• CPC Class Codes: H02K 5/1285 of the submersible type
• CPC Class Codes: H02K 5/132 Submersible electric motors H02K5/128 takes precedence
• CPC Class Codes: H02K 7/08 Structural association with bearings
• CPC Class Codes: H02K 7/085 radially supporting the rotary shaft at only one end of the rotor H02K7/086, H02K7/09 take precedence

Abstract

A submersible electric thruster operable to propel underwater vehicles, surface vehicles, amphibious vehicles, etc. The submersible electric thruster includes a stator assembly having a base, stator, windings, and bearings and an external rotor assembly having a cylindrical arrangement of permanent magnets with a hub that is secured to a shaft. The stator forms the center of the motor and the permanent magnets spin around the stator. A propeller hub is integrally connected to the rotor assembly with angularly spaced propeller blades extending radially from the propeller hub. An annular nozzle surrounds the propeller and motor, forming an inlet and outlet for water flow. A nose cone is connected to the stator assembly and a tail cone is integrally connected to the nozzle assembly. Supporting arms may extend from the stator assembly to support the nozzle and/or supporting arms may extend from the nozzle to the support the tail cone.

Claims

1. A submersible electric thruster comprising:

a stator assembly with a stator, electrical windings, bearings, and a base;

a rotor assembly with a shaft extending through the stator assembly that is connected co-rotatably to a plurality of magnets arranged about the stator that are driven by the electromagnetic forces of the stator and windings;

a propeller with a central hub that surrounds and is co-rotatably connected to the rotor assembly and with a plurality of angularly spaced propeller blades that extend from said central hub;

a nose cone that is connected to the stator assembly;

a nozzle that is connected to the stator assembly and provides an inlet and outlet for water flow;

a tail cone that is connected to nozzle; and

at least one chamber containing at least the stator and windings;

wherein the plurality of magnets of the rotor assembly are arranged radially outwardly of the electrical windings of the stator assembly to thereby rotate about the windings when driven by the electromagnetic forces provided by the stator and windings;

wherein the at least one chamber containing the stator and windings is configured to be flooded with water when the thruster is submerged; and

wherein a protective coating encapsulates the stator and windings to prevent water from contacting the stator and windings when the at least one chamber is flooded due to the thruster being submerged, and wherein the protective coating makes direct contact with the flooded water.

2. The thruster of claim 1 further comprising an electronics unit having a motor controller, the electronics unit being connected between the stator assembly and the nose cone, the electronics unit being disposed within one of the at least one chambers of the thruster that is flooded with water when the thruster is submerged, and wherein the electronics unit is sealed from the flooded water by a protective coating that encapsulates the electronics unit and is in direct contact with the flooded water.

3. The thruster of claim 1, further comprising a plurality of supporting arms that connect the stator assembly to the nozzle.

4. The thruster of claim 3 further comprising a plurality of recesses in the nozzle in which are disposed the ends of the supporting arms that connect the stator assembly to the nozzle.

5. The thruster of claim 1, further comprising a plurality of supporting arms that connect the nozzle to the tail cone.

6. The thruster of claim 1, further comprising an external electrical cable that extends through a wire hole included in the nose cone and provides electrical connections for powering and controlling the thruster.

7. The thruster of claim 1, wherein the nosecone is translucent or transparent, and further comprising a light emitting diode and associated electronics disposed in the nose cone.

8. The thruster of claim 1, wherein the nose cone is transparent, and further comprising a camera sensor and associated electronics disposed in the nose cone.

9. The thruster of claim 1, further comprising a protrusion extending from the nozzle providing a flat mounting surface and threaded holes for attachment.

10. The thruster of claim 9 further comprising a mounting bracket with holes to allow fixture to the nozzle and a set of mounting holes to allow fixture to a vehicle.

11. The thruster of claim 10, wherein the mounting bracket is oriented with the mounting holes on either side of the thruster or in front and behind the thruster.

12. The thruster of claim 10, wherein the nosecone is translucent or transparent, and further comprising a light emitting diode and associated electronics disposed in the nose cone.

13. The thruster of claim 10, wherein the nose cone is transparent, and further comprising a camera sensor and associated electronics disposed in the nose cone.

14. The thruster of claim 2, further comprising a plurality of supporting arms that connect the stator assembly to the nozzle upstream of the propeller, the upstream supporting arms having a hydrofoil shape that provides for low drag;

and

a plurality of supporting arms that connect the tail cone to the nozzle downstream of the propeller, the downstream supporting arms being shaped to minimize hydrodynamic drag.

15. The thruster of claim 14 further comprising a plurality of recesses in the nozzle in which are disposed the ends of the respective upstream and downstream supporting arms.

16. A submersible electric thruster comprising:

a stator assembly with a stator and electrical windings;

a rotor assembly with a shaft extending through the stator assembly that is connected co-rotatably to a plurality of magnets arranged about the stator that are driven by the electromagnetic forces of the stator and windings;

a propeller with a central hub that surrounds and is co-rotatably connected to the rotor assembly and with a plurality of angularly spaced propeller blades that extend from said central hub;

a nose cone that is connected to the stator assembly; and

a nozzle that is connected to the stator assembly and provides an inlet and outlet for water flow;

at least one chamber containing at least the stator and windings;

wherein the plurality of magnets of the rotor assembly are arranged radially outwardly of the electrical windings of the stator assembly to thereby rotate about the windings when driven by the electromagnetic forces provided by the stator and windings;

wherein the at least one chamber containing the stator and windings is configured to be flooded with water when the thruster is submerged; and

wherein a protective coating encapsulates the stator and windings to prevent water from contacting the stator and windings when the at least one chamber is flooded due to the thruster being submerged, and wherein the protective coating makes direct contact with the flooded water.

17. The thruster of claim 16 further comprising:

a tail cone located toward the rear of the thruster; and

an electronics unit having a motor controller, the electronics unit being connected between the stator assembly and the nose cone, the electronics unit being disposed within one of the at least one chambers of the thruster that is flooded with water when the thruster is submerged, and wherein the electronics unit is sealed from the flooded water by a protective coating that encapsulates the electronics unit and is in direct contact with the flooded water.

18. The thruster of claim 16, wherein the stator assembly further includes a base and a bearing tube that supports the stator and contains bearings, wherein the bearing tube and the base are formed as a unitary member.

19. The thruster of claim 16, wherein the rotor assembly further includes a ferrous ring within which the plurality of magnets are disposed, and wherein the ferrous ring acts to contain and focus the magnetic flux of the magnets and the magnetic flux of the stator and windings when the thruster is in use.