Electric engine mount design and structural analysis for rotary-wing UAVs

Purpose This study aims to design and optimize mounting brackets for electric motors in rotary-wing unmanned aerial vehicles (UAVs) to enhance operational efficiency, reduce carbon emissions and ensure mechanical reliability while accommodating diverse motor geometries for consistent functionality. Design/methodology/approach This research focuses on structural optimization of motor mounting brackets using aluminum alloy Al 7075-T6, selected for its superior strength-to-weight ratio and excellent fatigue resistance, widely used in aerospace applications. Precision sheet metal cutting and bending techniques were used to achieve cost-effective manufacturing while maintaining structural robustness. Finite element method simulations were conducted to evaluate stress distribution and deformation under various directional loading scenarios, simulating realistic operational conditions to validate the structural integrity of the bracket designs. Findings Finite element method analyses revealed that all bracket configurations remained well within the yield limits of Al 7075-T6, with stresses and displacements adhering to industry-standard safety thresholds. The designs effectively balanced mechanical strength, weight reduction and ease of assembly, ensuring reliable UAV performance. Research limitations/implications This study primarily addresses rotary-wing UAVs; extending research to fixed-wing or hybrid UAVs could broaden applicability. Real-world testing under extreme environmental conditions would further validate simulation results. Practical implications The optimized brackets enable lightweight, durable and cost-effective motor integration, enhancing performance and scalability for civilian and military UAV applications. Social implications By advancing low-emission aerial technologies, this research supports environmental sustainability, promoting eco-friendly UAV use in logistics and surveillance. Originality/value This study provides a novel approach to designing versatile, lightweight and robust motor mounting brackets, facilitating efficient electric motor integration and sustainable UAV systems.