Development of a High Power Density Drive System for Unmanned Aerial Vehicles

Unmanned aerial vehicles are characterized by a set of requirements, like high efficiency, resiliency, and reliability that conflict with the other main requirement of high power density aimed at minimizing the overall weight and size. This article proposes a novel, modular multiphase drive for a quadrotor drone, realized through the integration of an axial flux permanent magnet machine and a GaN-based power electronic converter. After an overview of the design process, starting from the propeller choice, a brief description of the system components is presented. Focusing specifically on the power electronic converter, the article then presents a full analysis of its electrical and thermal performance. Extensive experimental tests allows to validate the predictions of the design and simulation stages and demonstrated the expected high power density levels.