This article investigates the design of a 250 kW permanent magnet (PM) machine used for aircraft propulsion. The focus is to pursue high specific power (>20 kW/kg), high efficiency (>95%), and low thermal resistance direct-cooling design for the demanding aerospace applications. The proposed key-enabling technology is additively manufactured hollow conductors integrated with heat pipes. Compared to the existing high specific power PM machines for aerospace applications, the proposed design features a much lower speed – 5000 r/min without any torque amplifier, which helps promote the specific power of the overall system. Based on parametric finite-element analysis, tradeoff studies on a variety of winding configurations as well as geometrical parameters have been carried out, highlighting their impact on specific power, winding ac losses, and efficiency. AlSi ₁₀ Mg coil samples printed by direct metal laser sintering as well as thermal management system have been demonstrated to show the feasibility of the concepts.

中文翻译：

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与热管集成的增材制造空心导体：设计权衡和硬件演示


本文研究了用于飞机推进的 250 kW 永磁 (PM) 电机的设计。重点是追求高比功率（>20 kW/kg）、高效率（>95%）和低热阻直冷设计，以满足要求苛刻的航空航天应用。所提出的关键技术是与热管集成的增材制造空心导体。与现有用于航空航天应用的高比功率永磁电机相比，所提出的设计具有低得多的速度 - 5000 r/min，无需任何扭矩放大器，这有助于提高整个系统的比功率。基于参数有限元分析，对各种绕组配置和几何参数进行了权衡研究，强调了它们对比功率、绕组交流损耗和效率的影响。通过直接金属激光烧结和热管理系统打印的 AlSi ₁₀ Mg 线圈样品已经过验证，证明了这些概念的可行性。