Research on a Hybrid Cooling Topology Based on a Permanent Magnet Synchronous Motor With Tooth-Tip Span Angle Modulation Configuration

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Abstract
As aircraft increasingly transition toward more-electric/all-electric architectures, the demand for higher power density in aviation motor systems continues to grow. However, prolonged high-power-den-sity operation significantly intensifies the challenges of motor thermal management. To address this issue, this paper proposes a hybrid cooling topology based on a Permanent Magnet Synchronous Motor with Tooth-tip Span Angle Modulation Configuration (TSAM-PMSM), which inherently exhibits both high power density and high reliability. For the stator, cooling copper tubes using aviation kerosene as the coolant are integrated into the inter-phase air gaps and double-layer winding slots of the TSAM-PMSM. This enables long-term safe operation at high power density without requiring a separate heat exchanger, thereby further improving the system power density and simplifying the cooling system. By adding cooling slot structures around the copper tubes, low-reluctance magnetic paths are provided for the flux linked with the tubes, greatly suppressing eddy current losses in the copper tubes. For the rotor, a titanium-alloy hollow shaft with copper thermal bridges is proposed to address the heat dissipation challenge of the thin, high-heat-density copper shielding layer. This enhances the rotor’s thermal stability and further reduces the temperature rise of the permanent magnets. A Lumped Parameter Thermal Network (LPTN) is established for both the stator and rotor, enabling rapid analytical calculation of the steady-state temperature rise of key components in the TSAM-PMSM. FEA results demonstrate that the proposed hybrid cooling topology allows the TSAM-PMSM to operate continuously at a current density of 12 A/mm² while meeting the temperature rise requirement.

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