The constant growth of air traffic, the demand for performance optimization, and the need for decreasing both operating and maintenance costs have encouraged the aircraft industry to move toward more electric solutions. As a result of this trend, electric power required on-board of aircraft has significantly increased through the years, causing major changes in electric power system architectures. Considering this scenario, this paper gives a review about the evolution of electric power generation systems in aircraft. The major achievements are highlighted and the rationale behind some significant developments discussed. After a brief historical overview of the early dc generators (both wind- and engine-driven), the reasons which brought the definitive passage to the ac generation, for larger aircraft, are presented and explained. Several ac generation systems are investigated with particular attention being focused on the voltage levels and the generator technology. Furthermore, examples of commercial aircraft implementing ac generation systems are provided. Finally, the trends toward modern generation systems are also considered giving prominence to their challenges and feasibility.

In electrical machine design, thermal management plays a key role in improving performance and reducing size. End-windings are commonly identified as the machine hot-spot. Hence, lowering and predicting end-windings temperature are crucial tasks in thermal management of electrical machines. This paper proposes and investigates a non invasive but effective cooling method that aims for a uniform cooling of a machine's winding by implementing direct cooling on its end-windings. Modelling and experimental results show that a 25% hot-spot temperature reduction on a particular application can be achieved. To analyse the proposed technique in detail, an accurate but computationally-economic lumped parameter thermal network is developed. Comparison between a ‘standard’ thermal network and its simplified equivalent (with less nodes) is presented where the models are developed and fine tuned based on experimental data. All the above is used to investigate the potential of the proposed end winding cooling method with different configurations of the methodology.

Electrical machines for transportation applications need to be highly reliable, particularly if they drive safety-critical systems. At the same time, another main requirement is represented by the significant torque density, especially for aerospace, where weight constraints are extremely stringent. For achieving high peak torque, an effective strategy consists in supplying the windings with a current greater than the rated value; thus, thermally overloading the machine for limited time periods. However, if the insulation is overheated, the machine lifetime is shortened and reliability issues can arise. This paper experimentally investigates the influence of short-time thermal overload on the insulation lifetime for low voltage, random wound electrical machines. The analysis is performed on round enamelled magnet wire coils, which are aged by accelerated thermal cycles. The obtained results are statistically processed through a two parameter Weibull distribution. According to the findings of the experimental data post processing, a lifetime prediction model is built. This model is employed for predicting the lifetime consumption of a motor embedded into an electromechanical actuator for aerospace application.

Electrical machines are required to consistently perform their intended mission over a specified timeframe. The move towards transportation electrification made the electrical machines’ reliability an even stringent and predominant requirement, since a failure might cause severe economic losses, as well as, endanger human lives. Traditionally, the design procedure of motors conceived for safety-critical applications mainly relies on over-engineering approaches. However, a paradigm shift is recently taking place and physics of failure approaches / methodologies are employed to meet the reliability figures, while delivering an optimal design. The present work proposes and outlines a reliability-oriented design for low-voltage electrical machines. Thermal accelerated aging tests are preliminarily carried out on custom-built specimens. Once the aging trend of the turn-to-turn insulation system is assessed, the thermal endurance graph at several percentile values is determined and lifetime models are developed, for both constant and variable temperature operations. Finally, these models are used to predict the turn-to-turn insulation lifetime of motors meant for aerospace and automotive applications.

Modern electrical machines employed in transportation applications are required to provide high performance in terms of power (and torque) density. At the same time, being these applications safety-critical, a significant level of reliability and/or fault tolerance is expected. Among all the factors which can compromise motors reliability, partial discharges (PDs) inception is one of the most crucial, in particular for low voltage, random wound machines. This article presents an extensive experimental investigation on PDs in electrical machines for aerospace applications. Measurements are carried out using both sinusoidal and fast-rising pulses in a representative aerospace environment, emulating the typical ambient conditions encountered throughout a commercial aircraft mission, and beyond (i.e., down to 30 mbar). As a main result of the investigation, it is proved that electrical machines employed for actuating primary flight control surfaces feature a higher risk of PDs inception. Therefore, their insulation system demands an extremely careful design.

As the world of transportation keeps moving toward greater electrification, the main design objectives in terms of power density and efficiency of system components are becoming increasingly important. Meanwhile, transportation applications are also very safety critical. The extra stresses being seen by important components, such as electrical machines (EMs) and their insulation systems, to achieve the required performances, are accelerating the degradation of components, making them less reliable and shorting their lives. In general, lifetime consumption and degradation of components, such as for insulation systems of EMs, is still assessed through statistical methods (i.e., recording the number of imposed cycles until failure of a built prototype). This is a very timeconsuming and expensive process. In the mobile applications, such assessments can be the major bottleneck in the development timeline of an electrical product, especially for certification.