4-MW Class High-Power-Density Generator for Future Hybrid-Electric Aircraft
Dmitry Golovanov, David Gerada, Giacomo Sala, Michele Degano, Andrew Trentin, Peter H. Connor, Zeyuan Xu, Antonino La Rocca, Alessandro Galassini, Luca Tarisciotti, Carol Eastwick, S. Pickering, Patrick Wheeler, John Clare, Mykhaylo Filipenko, Chris Gerada
Abstract
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.