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DC Motor Technologies for Commercial Aerospace Applications

October 17, 2024
commercial-aerospace-motors

Several DC motor technologies and form factors are appropriate for the harsh conditions and special requirements of aerospace applications. Among them, brushless DC (BLDC) motors are characterized by their exceptional speed and position control, long life and high torque density, while brush DC motors come in small sizes boasting high power density and excellent speed-to-torque performance and minimal iron losses. BLDC motors can also be implemented as stand-alone units or as part of a more complete motion system that includes a custom housing with integrated gear train for easy installation. Here is a brief overview:

  • Slotted BLDC motors have coils inserted in the slots of the stator and offer a balance of a combination of benefits that includes high torque density and maximum speed, long life, low inertia, efficiency and protection against shock and vibration. These powerful motors are designed with thicker teeth inside the copper windings, thereby creating a smaller air gap between the iron and the magnets. Slotted BLDC motors laminated with stacked steel offer high efficiency and power density with low losses and the ability to withstand high peak torque. Portescap slotted BLDC motors are designed with windings that are placed in slots cut axially along the inner periphery for easier customization. Additional benefits include the ability to withstand harsh environments and a long lifetime.
  • Slotless BLDC motors use a cylindrical ironless coil made in the same winding technique as ironless DC motors. Using high energy permanent neodymium iron-boron or samarium cobalt magnets, motors with a slotless stator design exhibit acceptable core losses and stable operation at high speeds. Their larger air gap minimizes cogging torque while also reducing noise and vibration. Slotless BLDC motors generate lower EMI, making them appropriate for applications where interference with other avionic devices is a concern.
  • BLDC slotted motors with a flat outer rotor are designed to fit into tight spaces. This rotor configuration delivers high continuous torque for exceptional power density and smooth output. These attributes, along with easy customization, make BLDC slotted motors with a flat outer rotor particularly desirable for aerospace applications.
  • DC coreless motors offer many of the same features of a BLDC motor in a compact, coreless brushed unit. Without a core, these motors are inherently smaller and more lightweight than typical DC motors. They also accelerate faster, produce less EMI and ambient noise, while exhibiting smooth operation. In addition, coreless brushed-type DC motors are not subject to iron losses and offer lower Joule heating, resulting in exceptional efficiency. Portescap’s Athlonix™ family has two series designed to meet specific power, torque, lifetime and size requirements, with a host of customization options.

Optimize a DC Motor to Meet Your Specific Requirements

Finding the DC motor that meets your exact requirements while also addressing the inherently tough conditions and unique requirements of commercial aerospace applications is seldom easy. When it comes to custom DC motors, there are certain attributes to look for in a supplier. They include:

  • A consultative approach to motor system design
  • Support for integrated solutions
  • Flexible design capabilities to create systems that operate reliably in harsh environments.

At Portescap, we have a 40-year history of providing innovative precision motors and motion control products to the aerospace industry. Our off-the-shelf and custom precision DC motors resist thermal and mechanical extremes while delivering the power and long life that commercial aerospace applications demand — all in a compact, lightweight envelope. If an application calls for a customized motion system, we consult with our customers to meet the system’s exact requirements for reliability and performance.

Want to learn more? Read the full whitepaper here!