Investigation of Slot Shape and Associated Winding Configuration for Aerospace Actuator Motor

Electrification of aircraft systems has seen a continuous rise in recent years as the aerospace sector demands for increased power density and reliability. As electrical machine winding has a critical impact on the key aerospace design requirement, various competent stator structures were studied. The impact of stator slot shape on the winding is explored, whilst taking the electromagnetic and thermal performances as well as the manufacturability into consideration. The three key stator assemblies studied include semi open slot, open parallel slot and closed slot. The primary focus of the research was to identify the most suitable stator slot shape that makes winding manufacturing techniques predominately easier, whilst augmenting the copper slot fill factor. It is identified that having a modular or open parallel stator slot structure will enhance the slot fill factor by at least 15%. Maximisation of slot space and use of rectangular or square shaped wires are also identified as a benefit from these stators. These robust machine construction enables repeatable and easier manufacturing processes, as automated technologies such as edgewise, flatwise, concentrated or preformed windings can be implemented.