The Influence of Geometric Scaling on Power Density and Efficiency of PMSM Using High-Temperature-Resistant Electromagnetic Wire

As aviation machines demand higher power densities, the thermal limitations of traditional insulation have become a bottleneck. High-temperature-resistant electromagnetic wire (HT wire) enables windings to carry higher currents, offering a novel approach to improve power density. This method sacrifices efficiency to boost power density, yet the relationship between efficiency and power density remains unclear. This paper establishes an equivalent resistivity-temperature characteristic model for HT wire, derives the relationship between geometric dimensions and copper losses, and obtains performance maps for power density versus efficiency. The study demonstrates that the axial shortening approach significantly outperforms the radial shortening approach. The optimal solution achieves a 27.3% increase in power density while maintaining efficiency above 90%, validating the feasibility and effectiveness of the proposed method.