The goal of this project is to develop a torque-dense geared motor for actuating flaps of an aircraft. We propose to increase the torque density by using a novel configuration which seamlessly integrates a torque-dense motor with a torque-dense gear train. Such arrangement produce more torque in a smaller space as it fully utilizes the available space. In addition, the motor will be configured to produce high torque density by using recently developed soft and hard electromagnetic materials in an unique configuration to achieve high energy density. The scalability will be established by sizing a larger motor and conducting torque density analysis. In Phase I we propose to design the torque-dense motor, integrated gear train and controller and define their performance. Detailed design of all electromagnetic parts such as rotor, stator and housing will also be undertaken . Thermal management system that keeps the operating temperatures within the limits will also be designed using multiple paths, extended surfaces and low thermal resistance materials. The efficiency of the motor will be improved by applying recently developed ac loss reduction technology. A preliminary layout of the geared motor is the end result of this effort.
Benefits: The torque dense motors will find immediate application in railway traction motors, hybrid vehicles, aircraft generators, helicopter generators, motion control products, warehouse and construction vehicles, military and commercial aircraft and ship propulsion system
