Mar 22, 2024

Research at TU Dresden for innovative aviation propulsion systems of the future – Project: Electrical power units for hybrid-electric drive systems – (ELAN)

Elektrischer Motor von Rolls-Royce. — Elektrischer Motor © Rolls-Royce.

A consortium of Rolls-Royce Electrical, Schaeffler Aerospace Germany and the TUD Dresden University of Technology with the Institute of Lightweight Engineering and Polymer Technology (ILK) and the Institute of Electrical Power Systems and High Voltage Engineering (IEEH) has launched the ELAN project. The aim of this project is to develop electrical power units for hybrid-electric drive systems for eVTOLs and CS23 aircraft. In close cooperation with Rolls-Royce, the TUD is supporting the realization of the "Flightpath 2050" goals, which strive for sustainable and efficient aviation. Furthermore, efforts are being made to support the transformation of Lusatia through the further development of the local lightweight engineering industry and the establishment of new potential aviation suppliers.

In this project, the ILK is significantly involved in the research and development of new lightweight engineering methods for eVTOL drives. The ILK is currently concentrating on the development of the end shields and the shaft of the transverse flux motor for the electric drive. The aim for the end shields is to develop a topology-optimized fibre composite structure that saves mass and at the same time enables efficient heat dissipation. In addition to the end shields, the ILK is also looking at the drive shaft in terms of its lightweight engineering potential for electric drive systems, always keeping the overall system and global requirements in mind.

The ILK's tasks include a comprehensive analysis of the current reference structure made of light metal in order to determine the components with the highest lightweight design potential. A technology and design matrix is then created in order to optimize the components. After selecting a preferred variant, a load and functionally appropriate lightweight structure is iteratively developed and virtually validated. Finally, the real functional verification of the assembly is carried out under laboratory conditions.

At the same time, the ILK creates a catalog of methods for the design and layout of structural and functional elements that can be applied to future developments.

Propulsion Unit — Die elektrische Antriebseinheit für regionale Luftmobilität © Rolls-Royce

Simulation modell — das Simulationsmodell der Lagerschilde und Welle in der Antriebseinheit © ILK - TUD

The ELAN research and development project is funded by the Federal Ministry of Economics and Climate Protection (BMWK) in the aviation research program LuFo VI-2 under the funding code 20L2106A. The author is responsible for the content of this publication.

Project partnership with