This article describes the underpinning research, development, construction, and testing of a 4-MW multithree phase generator designed for a hybrid-electric aircraft propulsion system demonstrator. The aim of the work is to demonstrate gravimetric power densities around 20 kW/kg, as required for multi-MW aircraft propulsion systems. The key design choices, development procedures, and tradeoffs, together with the experimental testing of this electrical machine connected to an active rectifier, are presented. A time-efficient analytical approach to the downselection of various machine configurations, geometrical variables, different active and passive materials, and different thermal management options is first presented. A detailed design approach based on the 3-D finite element analysis (FEA) is then presented for the final design. Reduced power tests are carried out on a full-scale 4-MW machine prototype, validating the proposed design. The experimental results are in good agreement with simulation and show significant progress in the field of high-power-density electrical machines at the targeted power rating.

The power density of electrical machines for transport applications has become a critical aspect and target of optimization. This paper looks at the development of an intelligent, rapid, flexible, and multidomain tool to aid for system-level optimization of electrical machines within next-generation high power density applications. The electromagnetic, thermal, and mechanical aspects are wholly integrated, thus enabling the optimization including the nonactive mass. The implementation and overall architecture of the tool are described, and using a case study drawn from the aerospace industry, the tool is used to compare the power density of various surface permanent magnet topologies including single airgap and dual airgap machines, highlighting the particular suitability of the dual rotor topology in achieving the best power to mass ratio. Finally, the accuracy of the tool is highlighted by practical realization and experimental validation.

This paper describes the research and development of a 3kV active rectifier for a 4MW aerospace generator drive system demonstrator. The converter is fed by a multi-phase high speed/high frequency, permanent magnet generator. The main aim of the work is to demonstrate for the first time the feasibility of a MW-class generator system meeting future hybrid-electric propulsion requirements. A concept with multiple and isolated three-phase systems feeding different power buses is proposed to meet the availability requirements. Multiple converters (one for each three-phase system) are connected in series and/or in parallel to achieve the rated power and DC link voltage. This paper describes the key design concepts and the development and testing of the converter to meet the challenging application requirements. Reduced power tests are carried out on a full scale 4 MW converter prototype, validating the proposed design. The work represents a step forward in terms of voltage, power, and output frequency, with respect to the state of the art.

This paper describes a novel analytical methodology for modelling winding copper losses as a result of circulating currents (CC) in permanent magnet synchronous machines (PMSM). CCs are important to be considered at an early design stage especially in high frequency and high performance machines where sub-optimal design choices can lead to significant alternating current (AC) losses. Nowadays mainly FEM method is used for precise calculation of circulating currents. However, it suffers on significant computational time required for building models and simulation of circulating current effect that makes it inapplicable for optimization purpose. The paper demonstrates the computationally efficient methodology through comparison with FEM based models for high power density PMSM with concentrated winding and validation against experimental results for a stator section at the fundamental frequency from 500 Hz to 2000 Hz. The methodology allows simulation of CC and AC Ohmic losses when machine supplied by any current waveforms, for arbitrary size and location of the conductors in the slots. A key novelty of the proposed method is the utilization of subdomain (SDM) approach in conjunction with solution of a system of ordinary differential equations (ODE) for an equivalent electrical circuit of machine windings. This approach is precise and fast but has never been used before for circulating current loss evaluation in windings of electrical machines. The model is intended to be used at the design stage of an electrical machine where multiple geometric dimensions, winding configurations and conductor placement in the slot are considered towards an optimal design.