Design, Optimization and Initial Testing of a High-Speed 5-Kw Permanent Magnet Generator for Aerospace Application

Abstract

Abstract-The article presents a new topology of the high-speed synchronous electrical machines with permanent magnets with the tooth-coil windings with a stator magnetic core made of amorphous alloys for prospective unmanned aerial vehicles. This is a multidisciplinary design algorithm with optimization elements, which are proposed to design such machines. Based on the proposed algorithm, calculations of several topologies were performed by using computer simulation methods. In addition, the analysis of the rotor dynamics as part of the turbojet engine of the unmanned aerial vehicle and the calculations of the mechanical rotor strength were performed. To minimize the eddy-current losses in permanent magnets, the multicriteria optimization of the slotted zone was carried out by using genetic algorithms. A cooling system was proposed, and thermal calculations were performed. To verify the proposed design algorithm and to evaluate the efficiency of the amorphous alloy, a full-sized 5 kW experimental sample with a rotational speed of 60,000 rpm was created. Results can be used to create new promising UAVs and to design electrical machines for other industrial applications.

A Review on Methods to Reduce Weight and to Increase Efficiency of Electric Motors Using Lightweight Materials, Novel Manufacturing Processes, Magnetic Materials and Cooling Methods

“…As a thermal insulator, carbon fibers jacket, water / glycol mixture flows through the air gap, supplying ventilation to both the rotor and the tips of the stator tooth. Ismagilov et al [87] created a high-speed 5-kW PM generator for applications in aerospace for design, optimization and initial testing. The use of only air-cooling and failure of the liquid cooling system are the draw backs in the design.…”

Diagnostic Method of Rotor Cracks and Local Demagnetization by Using the Measuring Coils for the Permanent Magnet Synchronous Machines

“…where B r (ϕ) is a radial component of magnetic flux density; B M is a magnetic flux density on the PM surface; B rn max is a maximum radial component of magnetic flux density. When analyzing the magnetic field in PMSM, the Maxwell equations were used [23]:…”

High-Speed Electrical Machine With Radial Magnetic Flux and Stator Core Made of Amorphous Magnetic Material. Technologies, Trends and Perspective of Development

“…The main problems that all HSEM developers face are the provision of the rotor mechanical strength, the selection of the winding type and bearings. These aspects of the HSEM design are considered in [22][23][24] and are not given here.…”

“…Various bearings for HSEM are considered and selected. Recommendations are given in [22][23][24]. The most effective ones are gas or magnetic bearings, since they allow the high efficiency of the HSEM.…”