Integrated High Frequency Electric Propulsor for Turbo-Electric Aircraft

Within an 8-month, SBIR Phase II-E, we will demonstrate a higher power motor tailored for emerging applications. A full-scale motor with power capability of 1 MW, (speed to be determined from optimization studies on a ducted fan but expected to be around 6000-8000 rpm) will be built and part load tested. This capability is in line with the requirements of the electric propulsors for a number of electric/hybrid-electric regional jets under development. In this extended program, emphasis will be placed on propulsor integration. In addition to the design and fabrication of a 1 MW direct-drive motor, a closely integrated motor drive will be implemented using CREE SiC inverter modules and a custom passive cooling scheme. A 3-bladed propeller will be coupled with the motor to gain understanding on mounting mechanics, thrust transmission, and complicated rotor dynamics in order to inform the conceptual layout of full integration with a ducted fan.

The slot-less PM cantilevered rotor electric machine topology has applications to numerous NASA projects. While the initial target of the proposed technology was the Tail Cone Thruster of NASA's STARC-ABL, Hinetics has been tapped to adapt the technology to a generator for NASA's SUSAN sub-scale research vehicle. Another machine of the same topology, developed at UIUC, targeted parallel-hybrid electric propulsion. Other projects such as X-57 could benefit from lighter, better performing, and passively cooled electric motors.

The tightly integrated electric propulsor concept described in this proposal offers weight and efficiency advantages over a range of power and speeds. The technology could be applied to a number of emerging air vehicle concepts ranging from commercial transport airplanes to large on-demand mobility vehicles. Hinetics has also been exploring eVTOL applications with potential partners.

This is early/mid-stage (TRL 4) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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