Custom Brushless DC Motor
project name

Custom Brushless DC Motor

DC Motor


High performance motors for challenging locations and situations typically found in primary and secondary flight controls, fixed-wing, rotary-wing, missile and rocket fin drives and thrust vectoring

Problem Statement
Applications with unique characteristics do not lend themselves to commercial off the shelf (COTS) solutions. Ingenium Aerospace develops custom solutions for applications with unique environmental or performance concerns. For this reason, Ingenium was contacted to develop a motor capable of high power and rated for an altitude of 400,000 feet with a high duty cycle.

A COTS motor did not exist to satisfy the needs of several specific, high altitude applications, so Ingenium designed a motor with vacuum encapsulated windings for the three-phase motor windings and the resolver commutation. Since this motor would be operated while moving through an altitude range where corona effects are prevalent, Ingenium set the winding voltage at 150 VDC with a continuous current capability of 50 Amps and a peak capability of 100 Amps. The motor has a temperature sensing thermistor embedded in the winding end turns, so real time temperature data can be reported during flight. Two D38999 connectors were used to isolate the high power motor leads from the signal leads associated with the resolver commutation and thermal sensor. This motor has a no-load speed greater than 15,000 RPM and stall torque greater than 80 in-lbs. This unit is approximately 2.5 inches in diameter and approximately 8.2 inches long with a max temperature rating of 155 Degrees C.

Results & Outcome
Ingenium Aerospace has delivered a number of these units for numerous applications. These modules are fielded and operating successfully in numerous applications spanning air, space, land and sea. Some application examples are: Primary and secondary flight control systems (FCS), SpaceShip2 (SS2), WhiteKnight2 (WK2), horizontal stabilizer trim actuation, high attitude long endurance unmanned air vehicles, and fin control systems among others.