Maximizing Power Density in the Design of a 100 kW Geared e-Propulsion Unit

This paper proposes a highly integrated 3-in-1 e-Propulsion unit that exceeds current state-of-the-art power density, utilising low-risk, high TRL technologies. The design process of the e-Propulsion unit is outlined, including the development of a high integrity, fault-tolerant system design targeting DAL-A safety levels. The resulting system concept embodies redundancy throughout the electrical system - two sets of windings in the motor and redundancy built into the power electronics create a robust and efficient architecture. The electrical machine is connected to an optimised single stage planetary gearbox to realise output shaft speed and torque suitable for an eVTOL or eCTOL type application. Both systems are cooled and lubricated by a standalone cooling loop.