Less Iron and More Switches Increase Range

Current prototype motors and inverters for small aircraft electric propulsion have impressive efficiency of about 95 and 97% and typical power density of a little over 2kw/kg and 5kw/kg respectively. We can improve each of these metrics with a rigid winding which is formed in situ to increase slot fill and a 99.5% efficient inverter based on massively parallel, wide bandgap power switches. With independent Brains and Brawn sections, the inverter is scalable and can be distributed within the motor case, allowing fault tolerance and thermal integration benefits. The reduced weight and cooling needs represent an effective range enhancement of about 8% when configured for the X-57 cruise motors. Current prototype motors and inverters for small aircraft electric propulsion have impressive efficiency of about 95 and 97% and typical power density of a little over 2kw/kg and 5kw/kg respectively. We can improve each of these metrics with a rigid winding which is formed in situ to increase slot fill and a 99.5% efficient inverter based on massively parallel, wide bandgap power switches. With independent “Brains” and “Brawn” sections, the inverter is scalable and can be distributed within the motor case, allowing fault tolerance and thermal integration benefits. The reduced weight and cooling needs represent an effective range enhancement of about 8% when configured for the X-57 cruise motors. Objective: Demonstrate low loss winding and inverter design at a scale equivalent to the X-57 propulsors. Work Summary: Dyno test second iteration of 650 V 99.5% efficient distributed inverter Dyno test a five inch 20kw plate wound dual star motor Dyno test a rewound NASA prototype X-57 cruise motor Deliverables Complete X-57 high lift motor propulsion element Dyno test reports Cruise motor with improved windings Quarterly reports Final report with SF298
Benefits: Scalable technology, at least 10-100kW for main propulsion, electric actuation, auxiliary drives etc Our innovations are relevant to any motor and inverter application with a high demand for performance, typically aerospace and military