Design of an In-Slot Cooled Air-Core Flux-Focusing Permanent Magnet Synchronous Machine for Electric Aircraft Applications

High performance and reliable permanent magnet synchronous machines are potentially a key technology for enabling reduced emissions in future generations of sustainable aircraft. In this paper, a novel air-core flux focusing permanent magnet synchronous machine with carbon fiber shafting for aviation applications is presented. A low-fidelity analytical sizing tool is detailed for the motor topology. The sizing tool is used to explore design trades and create an example 100 kW flux-focusing motor for eVTOL applications. Higher fidelity finite element analysis was used to validate the predicted performance of the motor. The selected design is able to achieve roughly 97 percent efficiency and 6 kW/kg at a continuous operating power of 100 kW.