| dc.description.abstract | This thesis presents a complete structural design process of a rotor for a 250-kW dual rotor axial flux motor suited for single-aisle 150-200 passenger aircraft like the Boeing 737. The initial design space with geometric and material considerations is explored, accompanied by detailed sensitivity studies and comparisons with several different structural configurations in search of a mass optimal structure. The optimal rotor structure found utilized IM7/8552 carbon fiber composites for stiffness in 4 particular sections: the retaining ring, the magnet mounting disk, the spokes, and the root structures. For a nominal axial force of 5750 N at a 1.25 mm air gap distance, the optimal rotor structure which permits only 0.3 mm of deflection weighs only 406 g. Additionally, mass trade-off comparisons are presented using different Aerospace grade materials such as Aluminum 2024-T3 and Titanium 6Al-4V. It was found that the optimal masses of these structures are 831 g and 819 g respectively. A hybrid structure is also analyzed, with an aluminum primary structure and a carbon fiber retaining ring. This yielded an optimal mass of 600 g. Depending on a project manager’s goals, this study presents options for a trade study as far as mass-cost trade-offs in the development of a real axial flux motor meant for aircraft. | |
