Design and Experimental Validation of a High-Force-Density Tubular Permanent-Magnet Linear Motor for Aerospace Applications

This study presents the design, construction, and experimental validation of a high-force-density tubular permanent-magnet (PM) linear motor for aerospace applications. Initially, a strut structure was developed to enhance the contamination resistance and structural rigidity of the motor, which was validated through experimental testing. Subsequently, a motor topology was designed using two-dimensional finite element analysis to achieve a target thrust density of 400N/kg (specifically 500N/kg for the electromagnetic component) while maintaining a low detent force. The motor design was optimized for major pole number/slot number combinations of 8/24, 16/24, 20/24, 28/24, 32/24, and 40/24. The optimal design, featuring a three-phase 16/24 combination with a single-layer winding, demonstrated the highest force-to-mass density. The proposed design and its anticipated drive characteristics were experimentally validated using a prototype, confirming the effectiveness of the overall design.