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| Development Status and Research Overview of Propulsion Motors for eVTOL |
| Ju Xiaowei1, Long Jiaxing1, Zhang Fengge1, Cheng Yuan2, Cui Shumei2 |
1. Key Laboratory of Special Electric Machines and High Voltage Apparatus of Ministry of Education Shenyang University of Technology Shenyang 110870 China;
2. School of Electrical Engineering and Automation Harbin Institute of Technology Harbin 150001 China |
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Abstract Electric vertical takeoff and landing aircraft (eVTOL), often referred to as electric flying cars, offer significant advantages over land-based electric vehicles (EVs), such as the ability to take off and land vertically, bypass traffic congestion, and provide an environmentally friendly alternative. As a result, eVTOL holds great promise for future applications and has become a hotspot in sustainable transportation. These innovative aerial platforms are expected to play a pivotal role in accelerating efforts toward achieving carbon peaking and carbon neutrality goals. However, the development of propulsion motors for eVTOL represents a significant challenge. Research into eVTOL propulsion motors is still in its early stages. Though available technical data is limited, several key unresolved issues have emerged. (1) The selection of the final topological configurations of eVTOL propulsion motors remains uncertain. (2) The optimal design approach of the eVTOL propulsion system has yet to be determined. (3) The implementation of novel materials and advanced manufacturing processes requires further exploration. (4) Comprehensive reliability assurance methods are still under development.
Scholars worldwide have undertaken preliminary studies on eVTOL propulsion motors by analyzing aircraft configurations and operational requirements. Notable advancements have been made, including the development of high-power-density motor designs with optimized electromagnetic configurations, innovative integrated propeller-motor cooling systems featuring air-cooled designs, and advanced thermal management solutions using in-slot direct cooling with heat pipe technology. Significant progress has also been made in winding technology, particularly with the implementation of asymmetric high-density winding configurations. To enhance the reliability of propulsion motor systems, researchers have pioneered several breakthrough technologies, including multi-phase asymmetric winding arrangements that improve fault tolerance, integrated modular motor drive (IMMD) systems for better integration of power electronics, and multi-motor cooperative control architectures that ensure stable eVTOL operations. Additionally, the incorporation of cutting-edge manufacturing techniques, such as metal additive manufacturing (3D printing) and the use of wide-bandgap semiconductor devices like silicon carbide (SiC), has led to substantial improvements in propulsion motor performance, including increased power density, enhanced efficiency, and improved thermal management.
This paper provides a comprehensive review of current propulsion motor technologies, covering the classification of eVTOL configurations and transportation parameters. It also examines the existing research in four key areas: (1) parameter determination and design methods for eVTOL propulsion motors, (2) high power/torque density implementations, (3) strategies for enhancing reliability, and (4) vibration/noise reduction techniques. Existing EV traction motors are compared, with a detailed analysis of the typical flight conditions and key design challenges. Finally, the paper summarizes the design approaches aimed at achieving high-density, high-reliability, and low-noise propulsion motors for eVTOLs.
In conclusion, to meet the growing performance and reliability demands of eVTOL, future research will focus on four key areas. (1) The development of high-power/torque-density motor designs with innovative winding and rotor configurations; (2) The integration of advanced thermal management systems, including 3D printing and cooling techniques, such as air-cooling fins and in-slot heat pipe cooling; (3) Design strategies for improving reliability and reducing vibration/noise, including multi-phase windings, modularization, distributed drive technologies, and harmonic injection; (4) The development of unified electric propulsion systems capable of seamless ground-air operation and adaptability to multiple environments (ground, underwater, aerial).
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Received: 25 March 2025
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2025, Vol. 40 
