High Power Density Motor for Light Electric Aircraft – Design Study and Lab Tests

Following the trend and guidelines of the More Electric Aircraft (MEA), the aviation industry is currently focusing on the use of electric motors as the main propulsion units. This challenge is limited mainly by the relatively low capacity of available power sources. Another major aspect is the development of electric motors with High Specific Power (HSP) and high Torque per unit Rotor Volume (TRV). This paper deals with the motor intended as one of the propulsion motors for a light two-seater aircraft. The motor has a maximum power of 90 kW for a rotational speed of 3500 rpm and weight 18 kg. The article presents an analysis of the most important issues at the motor design stage, the physical model and the results of laboratory tests. The main attention was paid to the development of a motor solution that meets the basic design requirements, including, above all, limiting the motor’s weight. For this purpose, the following are analyzed: the selection of the appropriate type of motor, the selection of slot-pole combinations, the type of permanent magnets, the type of sheets in the stator core and issues reducing rotor losses. The strength analysis of the main mechanical elements is also presented.