Development of a Maxwell X-57 High Lift Motor Reference Design

NASA's all-electric X-57 airplane will utilize 14 electric motors, of which 12 are exclusively for lift augmentation during takeoff and landing. This report covers the design and development process taken to create an open reference model representative of the 12 lift augmenting motors. A combined worst case scenario was used as the design point, which represents the simultaneously occurring worst case aspects of thermal, static stress, electromagnetic, and rotor dynamic conditions. This work also highlights the tightly coupled nature of aerospace electric motor design, requiring constant iteration between all disciplines involved. Further adding to the uniqueness is the cooling method, which is limited to nacelle skin forced convection cooling only, no internal air flow is permitted. The stator outer diameter limit of 156.45 mm greatly impacts the degree of coupling between the electromagnetic design with the thermal analysis. The permanent magnet synchronous motor developed here operates between 385 V and 538 V, at a peak current of 50 A. Detailed electromagnetic, thermal, static load, and rotordynamic analysis was completed for this electric motor; all of which are required for a full design. The rotordynamic analysis took into consideration the motor housing which is designed specifically for this motor. The final electric motor has a mass of 2.34 kg, produces 24.1 Nm of torque with a specific power of 5.56 kW/kg, and has an efficiency of 96.61% at the combined worst case design point.