Maximum Power Density and Safety in Aviation
Redesign for High-Speed Motors
In cooperation with a supplier to the aerospace industry, PACK LitzWire realized the redesign of a high-performance electric motor. By using a profiled safety HF litz wire, high speeds could be thermally controlled, and at the same time, strict safety standards were met with minimized installation space.
The Application
The initial situation in the project was challenging: An existing electric motor for an aerospace application was to be made significantly more compact as part of a redesign, without compromising performance. At the same time, the specifications required very high speeds to perform the necessary mechanical work.
The Challenge
This combination led to a thermal dead end with conventional windings: The high electrical frequencies caused massive AC losses (skin and proximity effects), which could hardly be dissipated in the now miniaturized housing. In addition, there were the critical environmental influences of aviation: The motor had to withstand extreme temperature fluctuations, strong vibrations, and the altered insulation conditions at high altitudes.
Solution Strategy
PACK LitzWire, together with the customer's development engineers, analyzed the loss mechanisms and the geometric restrictions of the stator. The answer to the conflicting requirements of miniaturization and high-frequency capability was a thin RUPALIT® Safety litz wire in a profiled design.
Technically, three key design variables were addressed simultaneously: First, the ultra-fine individual strands drastically minimized eddy current losses at high speeds. Second, the litz wire was *profiled*—changing from a round to a rectangular cross-section. This enabled a significantly higher copper fill factor, reducing ohmic resistance and improving heat dissipation.
Result
The decisive aspect for aerospace certification, however, was the insulation system: The "Safety" version of the litz wire used guaranteed compliance with strict safety standards through its reinforced insulation and offered the necessary dielectric strength even under the difficult pressure conditions at altitude. The result of the redesign was an electric motor that, despite smaller dimensions and higher speeds, runs absolutely thermally stable, is mechanically durable, and offers all safety reserves for use above the clouds.
RUPALIT® Safety Profil
This VDE-certified structure sets new standards for safety in power electronics. Experience significant size reduction and accelerated winding processes by eliminating separate layer insulation.
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