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Design and Simulation of an Enhanced Cooling Structure for Electro-Hydrostatic Actuator Motor in Hypersonic Aircraft
Zhaoxiong Wang a and Yunhua Li b
aGraduate Student, School of Automation Science and Electrical Engineering, Beijing University of Aeronautics and Astronautics, Beijing 100191, P.R. China.
bProfessor, School of Automation Science and Electrical Engineering, Beijing University of Aeronautics and Astronautics, Beijing 100191, P.R. China.
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Abstract:
Thermal management is a key barrier to the safe operation of electro-hydrostatic actuators in hypersonic aircraft, where severe aerodynamic heating and time-varying actuation loads can drive permanent-magnet motor temperatures toward critical limits. To address excessive temperature rise, this paper proposes a novel integrated axial Z-shaped liquid cooling channel for the electro-hydrostatic actuator motor housing to enhance heat dissipation performance. A comprehensive mathematical model is established, and computational fluid dynamics simulations are employed to evaluate the thermal-hydraulic characteristics of the design. Comparative simulations were conducted under two typical flight conditions and a full mission profile to benchmark the Z-shaped channel against the original coil-shaped channel. The results demonstrate that under the attitude adjustment condition, the Z-shaped channel reduces the average housing, stator and winding temperatures by 4.1%, 9.2% and 8.6%, compared with the coil-shaped channel. Under the peak-load condition, the corresponding reductions are 3.6%, 10.9% and 4.6%, Transient simulations over the full flight profile indicate that all component temperatures remain strictly below the 135℃ safety limit, with the maximum housing temperature maintained at 128℃. These findings confirm that the proposed Z-shaped cooling structure significantly improves heat dissipation uniformity and the thermal safety margin for actuator systems in hypersonic aircraft.
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Keywords: electro-hydrostatic actuator, enhanced cooling structure, motor heat generation, computational fluid dynamics.
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©
2026
CSME , ISSN 0257-9731
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