Stator Design for 1 Megawatt High-Speed Radial-Flux Surface Mounted PM Motor for Aerospace Applications

Abstract

In an attempt to meet rigorous emission reduction targets, the global aviation industry is undergoing a paradigm shift toward sustainable propulsion systems. Electrification of aircraft propulsion is a promising strategy to reduce carbon footprints and improve operational efficiency. However, there are numerous technical challenges in the path of achieving megawatt-level electric propulsion in aerospace applications, especially with regard to mechanical robustness, power density, and thermal management. The stator design and analysis for a 1-megawatt (MW), high-speed (20,000 RPM), radial-flux surface-mounted permanent magnet (PM) motor optimized for aerospace applications is presented in this thesis. The stator meets crucial aerospace requirements, such as structural stability, manufacturability, and thermal reliability, which will be validated by FEA results which includes Static Structure and Steady State Thermal tests which were coupled with worst case scenario boundary conditions. The system achieves improved power density and operational reliability by optimizing the stator's geometry and internal support features. The proposed design also features flooded liquid cooling architecture with embedded channels that allow coolant to pass through the stator core efficient thermal management. These channels are possible due to manufacturing stator housing by additive manufacturing using AlSi10Mg. This research provides a foundational step toward the realization of compact, efficient, and robust megawatt-class electric propulsion systems for next-generation aircraft. The proposed stator design serves as a benchmark for future developments in electric aviation, paving the way for cleaner and more efficient air travel.