KORALU - Compact, resource-efficient drives for climate-neutral aviation

Initial situation and problem definition

Electric drives are considered a key technology for a climate-neutral air transportation system. Particularly compact and power-dense machines with concentrated windings are increasingly being used for this purpose. While the operating phase of such drives has already been intensively researched, a life cycle-oriented design approach that systematically incorporates aspects such as dismantling, reuse and recycling has been lacking to date. In addition, conventional manufacturing processes reach their limits when it comes to realizing complex coil geometries. This is where the KORALU project comes in: It combines the potential of additive manufacturing with sustainable machine design. The aim is to significantly improve electric drives for aviation in terms of efficiency, resource utilization and end-of-life capability - while simultaneously reducing development and production time.

Project goals

KORALU aims to systematically make electric drives for aviation more sustainable and efficient. By substituting conventional round wire coils with additively manufactured shaped coils, electrical losses are to be reduced by 20%, efficiency increased and the winding weight reduced by up to 50% - for example through the use of aluminum. At the same time, material and resource efficiency will be increased by 25% through targeted end-of-life concepts. The project also aims to reduce development time by 30% through a model-based, automatable design process chain. This creates the conditions for cost-efficient, lightweight and recyclable drives of the next generation.

Solution approach pursued

The KORALU project is pursuing a holistic approach that combines additive manufacturing, automated design methods and life cycle planning. The focus is on the development and validation of a motor with additively manufactured aluminum coils. These enable higher power density, improved heat dissipation and significant weight savings thanks to geometric flexibility. At the same time, additive manufacturing enables the economical production of small quantities - a major advantage in the aviation sector. The integration of end-of-life concepts as early as the design process ("design for disassembly") ensures increased recyclability of components. A model-based design chain bundles the complex requirements of electromagnetics, thermal engineering, production and recycling in a development process that can be automated. This opens up both technological and ecological optimization potential. KORALU thus makes key contributions to Industry 4.0, sustainable production and climate-neutral flying - in line with the goals of the LuFo climate focus.