ZeroAvia, a pioneering developer of electric propulsion technology for aviation, has established a new manufacturing center in Washington where it plans to produce some of the components for its systems while also opening up the sale of them to others. Two novel permanent magnet motors along with power electronics, fuel cell and hydrogen products are among the components being put on the market. A 660 kW max-power direct-drive motor can reach speeds up to 2,200 rpm, and the HyperCore 900kW modular motor is capable of speeds up to 20,000 rpm.
The HyperCore is a permanent magnet electric machine for applications ranging from 900kW up to 10MW. The fully integrated motor-inverter system is designed to be powerful, compact and ultra-efficient with 4 silicon carbide inverters. Designed for high altitude and unpressurized areas, its thermal, mechanical and electrical integration are optimized for high reliability and long life time by reducing cable weight, interfaces and coupling, connectors. The inverters are fully equipped for high-speed bus communication and a high degree of redundancy and availability.
ZeroAvia Motor is a high-efficiency machine developed to support the company’s ZA600 hydrogen-electric powertrain for commercial aircraft up to 20 seats. The 660 kW 4×3 phase permanent magnet synchronous machine 400–830 Vdc motor is surface permanent magnet based with bidirectional operation, specifically designed for direct drive installations mounted to a propellor. The three phase AC current from the Inverter drives the motor bidirectionally.
The stator core is divided into 4 sections to enhance fault tolerance and allow higher input current from the inverters. The motor is designed and produced following aerospace standards, allowing a high-power density and reduced weight with advanced thermal management. Optimized cooling allows for very efficient heat transfer within the motor to allow it to run cooler and for longer. It has a spline interface for mounting a gearbox or accessory drive to the rear.
Certification work for the ZA600 engine for up to 20 seat aircraft is underway, and the underpinning technology for the ZA2000 engine for up to 90 seat aircraft in advanced development. In April, the company opened a new 136,000 sq ft manufacturing facility at Paine Field in Everett, Washington, north of Seattle where it plans to manufacture the motor and power electronic components. A second site is planned for production of fuel cell systems.
“Today we set forth plans that detail how we are going to bring our engines to market for commercial aircraft as well as the additional market potential in components generated by our pursuit of aerospace applicable fuel cell and electric propulsion technologies,” said Val Miftakhov, founder and CEO of ZeroAvia at the opening ceremony.
“We intend to secure as much market share for commercial aviation propulsion systems as possible as this will enhance shareholder value and ensure we deliver in tackling climate impact in the sector. While the market for our powertrains is thousands of engines across commercial aircraft, there will be other applications that are not strategically aligned with our full engine offering, but where our technologies can play a major role in the supply chain for other OEMs.” For more info, see www.zeroavia.com.
