High-Performance Electric Drives for Aerospace More Electric Architectures Part I – Electric Machines IEEE PES Conference Tampa, Florida, USA June, 27th Evgeni Ganev, Ph.D. Chief Engineer – Electromechanical Power Systems Honeywell International Engineering and Technology Torrance, California [email protected] Paper Objective h Review the latest tendencies in the aerospace industry for high performance electric drives (HPED) h Obtain electric machines (EM) for HPED used in more electric architecture (MEA) for aircraft, spacecraft and military ground vehicles h Introduce a statistical method for electric machine selection and optimization used for HPED 07GM0408 2 Approach h Tendencies in MEA summarized h Influence of the new distribution buses understood h Six Sigma theory used related to critical-to-quality (CTQ) h Weight, volume, reliability, efficiency and cost CTQs addressed to develop an optimized system h Methodology for EM selection and optimization demonstrated h System approach used for overall machine selection and optimization h An example of high speed high performance EM application shown 07GM0408 3 Critical-to-Quality Characteristics h CTQ – one of a select few characteristics that can have significant impact on product performance h Following CTQs are addressed to develop balance among them resulting in an optimized design h Weight (W) most important CTQ for aerospace h Volume (V) recently when the installed electric drives and overall power electronics content is increased substantially h Reliability (R) directly affects mission success and performance, maintenance, repair and dispatch ability h Efficiency (E) becomes a major driver for fuel saving h Cost (C) is directly related to the affordability of a new platform 07GM0408 4 Basic Relations OD = F(RWW , RWV , RWR , RWE , RWC) (1) RWi = RCi*CTQi (2) i =1, 2, 3, …, m m = number of selected CTQ CTQi = fi (KC1,…KCj,…KCn) j =1, 2, 3, …, n (3) n = number of selected KC W = fW (KC1,…KCj,…KCn) V = fV (KC1,…KCj,…KCn) R = fR (KC1,…KCj,…KCn) E = fE (KC1,…KCj,…KCn) C = fC (KC1,…KCj,…KCn) (4) OptimalDesign DesignFunction FunctionUsed Usedfor forQuantification Quantification Optimal 07GM0408 5 Process Flowchart MultipleIterations Iterationsfor forOptimal OptimalDesign DesignRequired Required Multiple 07GM0408 6 Electric Machine Classification Electric Machines for Aerospace Brushless Synchronous Wound Field Asynchronous Permanent Magnet Tooth Stator Tooth 2 poles Brush Synchronous Slip Ring Reluctance Squirrel Cage IM Switched Reluctance Toothless 2 poles • • • Toothless Stator Tooth Multiple poles DC Brush PM • Toothless Multiple poles • • • IM SRM DC Brush PM PMM Tooth 2 poles PMM Tooth Multi Poles PMM Toothless 2 poles PMM Toothless Multi Poles SevenWidely WidelyUsed Usedin inAerospace AerospaceEM EMSelected Selected Seven 07GM0408 7 EM Key Characteristics h 7 EM rated for 14 KCs in 4 categories h Electrical performance h Mechanical performance h Thermal /cooling h Losses / losses distribution Machine Type Key Characteristics DC Brush PM IM SRM PMM Tooth 2 Poles PMM Tooth Multi PMM Tooth-less 2 Poles PMM Toothless Multi KC 1 Rotor Losses 1 6 6 10 10 10 10 KC 2 Stator Losses 10 4 4 5 6 4 5 KC 3 Windage Losses 3 5 1 9 9 10 10 KC 4 Rotor Thermal Limitations 6 8 10 4 4 4 4 KC 5 Cooling Options 1 5 5 9 9 10 10 KC 6 Rotor Mechanical Limitations 1 5 7 9 9 10 10 Torque-toInertia Ratio 6 5 5 9 9 10 10 KC 8 Torque Pulsation 2 9 3 6 6 10 10 KC 9 Compatibil-ity with Bearings 2 5 5 9 9 10 10 High-Speed Capability 1 5 7 9 9 10 10 Short Circuit Behavior 1 10 10 4 4 3 3 Machine Complexity 5 7 10 9 9 8 8 KC 13 Current Density 1 7 7 10 10 8 8 KC 14 Power Density 1 7 8 10 10 8 8 41 88 88 112 113 115 116 KC 7 KC 10 KC 11 KC 12 TOTAL ExtensiveExperience ExperienceUsed Usedto toDevelop DevelopKCs KCsand andTransfer TransferFunctions Functions Extensive 07GM0408 8 Turbo-compressor Application • • • • • • • • • 100 krpm / 17 KVA • • Contamination free air flow to fuel cell Compliant foil air bearings (no lubricants) Low production cost Zero Maintenance Reliable - one moving part Lightweight/Compact Efficient High temperature capable expander/turbine Variable geometry turbine maximizes efficiency Modular 15 kg/15 liters LongOperating OperatingLife LifeWithout WithoutLubrication Lubrication Long 07GM0408 9 Turbo-compressor Application – Key Components Rotor • • • • • • Samarium cobalt magnet material 2 poles magnet INCONEL sleeve Tie shaft assembly Mixed flow compressor wheel Radial inflow turbine wheel Foil Bearings • • • • • • • High-speed efficiency Compact No maintenance Up to 80k hours of continuous operation 50k start/stops Low life-cycle costs Over 30 years of proven performance Stator • • • • Tooth design 3 phase lap windings Silicon steel M16 5 mill Copper wire quantum insulation 07GM0408 10 MEA Tendencies Affecting Machines for HPED h Voltages of the distribution busses are being increased 115 to 230 Vac and 270 to 540 Vdc – corona issues h Transition from 400 Hz CF bus to VF and DC eliminates the advantage of IM h DC Brush PM machine is in process of being replaced with synchronous PMM due to reliability and speed limitations h The PMM family is best suited for HPED applications h Tooth PMM replaces toothless due to higher power density and improvements in foil bearings HigherSpeed Speedand andIncreased IncreasedPower PowerDensity Densityis isDemanded Demanded Higher 07GM0408 11 Conclusion h Statistical method for optimal EM design introduced h Key characteristics for 7 EM defined in relative terms h Methods for machine selection, optimization and design priorities are discussed h Transfer functions and optimal design functions developed h Work is in progress to address motor controllers NewTools Toolsfor forFast FastElectric ElectricDrives DrivesDesign Designand and New Optimizationare areRequired Required Optimization 07GM0408 12
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