In the aerospace field, the starter motor is the core component of the engine starting process, and its performance directly affects the reliability and operational efficiency of the aircraft. As aerospace technology advances towards higher performance and more complex operating conditions, the deep integration of starters and aerospace engines has become an inevitable trend. Among them, material and structural innovation in ultra-high temperature environments, as well as the technological development of micro starters for micro nano satellites, represent the forefront exploration directions in this field.
1、 Material innovation of starter motor in ultra-high temperature environment
Aerospace engines generate extremely high temperatures during operation, especially in the vicinity of the combustion chamber and turbine. The starter must be able to operate stably in such ultra-high temperature environments. Traditional metal materials may experience strength degradation and creep at high temperatures, which cannot meet the stringent requirements of modern aerospace engines for starters. Therefore, new ceramic based composite materials and carbon carbon composite materials have emerged.
（1） New Ceramic Matrix Composite Materials
Ceramic based composite materials have advantages such as high melting point, low density, high hardness, and good chemical stability. In ultra-high temperature environments, it can maintain structural integrity and provide reliable mechanical support for the starter motor. For example, silicon carbide ceramic matrix composite materials are mainly composed of a silicon carbide ceramic matrix and a reinforcing phase. Enhanced phases can effectively improve the toughness of materials and prevent brittle fracture at high temperatures. By optimizing the preparation process and precisely controlling the microstructure of the material, its performance at high temperatures can be further improved. This material has broad application prospects in components such as starter housings and gears, and can significantly improve the high-temperature resistance and reliability of starter motors.
（2） Carbon carbon composite materials
Carbon carbon composite material is a composite material with carbon fiber as the reinforcement and carbon as the matrix. It has excellent high-temperature mechanical properties, and its strength not only does not decrease but also increases in high-temperature environments above 2000 ℃. Meanwhile, carbon carbon composite materials also have good thermal conductivity and low coefficient of expansion, which can effectively resist thermal shock. The key components of the starter motor, such as the rotor and stator, are made of carbon carbon composite materials, which can maintain good electromagnetic and mechanical properties at high temperatures, improving the efficiency and reliability of the starter motor. However, the preparation process of carbon carbon composite materials is complex and costly, and further research and optimization are still needed to achieve their large-scale application in the aerospace field.
2、 Structural design optimization of starter motor in ultra-high temperature environment
In addition to material innovation, optimizing structural design is also crucial for improving the performance of starter motors in ultra-high temperature environments. Reasonable structural design can effectively reduce thermal stress, improve heat dissipation efficiency, and ensure the normal operation of various components of the starter motor.
（1） Thermal protection structure design
In order to protect the electronic components and mechanical parts inside the starter from high temperature invasion, it is necessary to design effective thermal protection structures. A common method is to use air-cooled or liquid cooled technology, by setting cooling channels inside the starter housing, introducing cooling medium (such as air or coolant), and taking away heat. In addition, a high-temperature insulation coating can be applied to the surface of the starter motor to further reduce heat transfer to the interior. For example, using ceramic insulation coatings can form a layer of insulation barrier at high temperatures, effectively reducing the transfer of heat.
（2） Lightweight structural design
In the aerospace field, reducing weight is crucial for improving the performance of aircraft. Therefore, the structural design of the starter motor needs to achieve lightweight as much as possible while ensuring strength and rigidity. By adopting advanced topology optimization technology, the distribution of materials can be optimized based on the force situation of the starter, unnecessary materials can be removed, and the structural weight can be reduced. At the same time, adopting an integrated design concept reduces the number of components, lowers the weight of connecting parts, and improves the overall integrity and reliability of the structure.
3、 Technical challenges and breakthroughs of micro starter motors for micro nano satellites
With the development of aerospace technology, micro nano satellites have been widely used in fields such as Earth observation, communication, and scientific experiments due to their advantages of low cost, short development cycle, and high functional density. As a key component of micro nano satellites, micro starters face a series of unique technological challenges.
（1） Ultra small size and high integration requirements
The volume and weight limitations of micro nano satellites require micro starters to have ultra small size and high integration. This requires the adoption of new concepts and methods in design, highly integrating multiple functional modules such as motors, transmission mechanisms, and control circuits. For example, using System on Chip (SoC) technology to integrate control circuits on a single chip reduces the volume and weight of external circuits. At the same time, research and development of new micro nano manufacturing processes such as photolithography, etching, microelectromechanical machining, etc., to achieve precise manufacturing and assembly of micro starter components.
（2） Low power design
Micro nano satellites are typically powered by solar cells, which have limited energy resources. Therefore, micro starters must have low power consumption characteristics to extend the working life of satellites. In terms of motor design, efficient electromagnetic materials and optimized winding structures are used to improve motor efficiency and reduce energy consumption. At the same time, optimize the control strategy and dynamically adjust the working state of the starter according to the actual needs of the satellite to avoid unnecessary energy consumption.
（3） Electromagnetic Design of Micro motors
Micro motors are the core components of micro starters, and their electromagnetic design faces many challenges. Due to its small size, the air gap magnetic field distribution of the motor is uneven, which can easily lead to torque fluctuations and reduced efficiency. To solve this problem, advanced electromagnetic analysis software is needed to accurately calculate and optimize the magnetic field of the motor. At the same time, researching new permanent magnet materials and electromagnetic structures to improve the power density and operational stability of motors.
（4） Application of Micro Electro Mechanical Systems (MEMS) Technology
MEMS technology provides new opportunities for the development of micro starters. Through MEMS technology, sensors, actuators, and microprocessors can be integrated onto a tiny chip to achieve intelligent control of micro starters. For example, by integrating micro accelerometers and gyroscopes, real-time monitoring of satellite attitude changes can be achieved, providing accurate feedback information for starter control. Meanwhile, MEMS technology can also achieve mass production of micro starter components, reducing costs.
The deep integration of starter motors and aerospace engines is one of the key factors driving the development of aerospace technology. By innovating materials and structures in ultra-high temperature environments, as well as breaking through the technical challenges of micro starters for micro nano satellites, the performance and reliability of starters can be significantly improved, laying a solid foundation for the future development of the aerospace industry. With the continuous advancement and innovation of related technologies, it is believed that starter motors will play a more important role in the aerospace industry.
