Design of an Integrated Inductor for 45kW Aerospace Starter-Generator

Abstract

A close physical and functional integration of passive components is required to make an efficient and power dense overall system. Such power dense systems are a prerequisite in aerospace and marine applications. This paper presents a design of an integrated rotor-less inductor for the application of a 45kW aerospace starter-generator. The impact of high current density inductor is investigated and compared with traditional core inductor in terms of total weight and volume. Both inductors are sized using area product approach and its design parameters are validated using finite element analysis. Comparative analysis between the traditional core and the integrated inductor has shown a significant reduction in total weight and volume. The total weight of the integrated inductor is reduced by 55.4% whereas the total volume is reduced by 52.7% when compared to traditional air cooled core inductor.

Novel Permanent Magnet Synchronous Motor With Integrated Filter Inductor, Using Motor's Inherent Magnetics

“…Such compact systems are prerequisite in aircraft and automotive applications. In order to overcome these downsides, the integration of passives needs to be introduced from functional and physical point of view [4][5][6][7][8][9].…”

“…This is only required if the electrical insulation does not comply with the dv/dt of the power switches. In [7][8][9], novel options to integrate the passive filter inductors were introduced within the housing of the motor or generator. The novel options include: motor-shaped rotational inductor and motor-shaped rotor-less inductor.…”

Thermal Design of an Integrated Inductor for 45kW Aerospace Starter-Generator

“…In comparison, the rotational inductor can only be employed for high speed motor drive systems. In [8], author has presented a design of motor-shaped rotor-less inductor adopted for 45kW aircraft starter-generator. This integrated inductor was designed and sized at current density of 18A/mm 2 which uses the existing cooling system of the starter-generator.…”

“…This paper presents the thermal investigation of an integrated rotor-less inductor proposed in [8] which is adopted for a 45kW aerospace starter-generator. In the next section, design procedure of the inductor using area product approach is discussed.…”

“…Where, is the window utilisation factor In general, for inductor, window utilisation factor typically varies from 0.45 to 0.55 in order to provide enough space for bobbins, slot liner and the wire insulation [8]. By substituting (3) in (2), we have, =…”