Abstract
This paper presents the manufacturing challenges of a transverse flux alternator for an aerospace application. For fault tolerance, four independent isolated phases are required to deliver a specific power at low speeds, whilst at over speed, there is a strict limit on the short circuit current. A transverse flux machine (TFM) was selected due to its high inductance combined with the modular nature of separate phases lending itself to fault tolerance. The stator consists of pressed soft magnetic composite (SMC) segments. The authors explore the electromagnetic, mechanical, and assembly design challenges of the machine. It is shown that mechanical design aspects of the segments are of equal importance to the electromagnetic design and optimization. Simple design choices have allowed the same component to be used as all the stator segments, despite the requirement of a 90° electrical phase difference between phases and a tooth offset of 180° electrical within each phase.
Highlights
Engine control electronics in civil aerospace require a dedicated fault tolerant power generation system to prevent a loss of aircraft power that might cause thrust control failure
It has been shown that this can be achieved through a segmented radial flux permanent magnet alternator [1,2]
This study aims to explore assembly and manufacturing challenges of a high speed transverse flux machine (TFM) for a civil aerospace application
Summary
Engine control electronics in civil aerospace require a dedicated fault tolerant power generation system to prevent a loss of aircraft power that might cause thrust control failure. Electrical, thermal, and mechanical isolations are required between phases, in addition to the ability to run short circuited indefinitely. It has been shown that this can be achieved through a segmented radial flux permanent magnet alternator [1,2]. Segmentation allowed for an improved assembly process and better coil fill factor compared to historical designs relying on magnetic slot wedges. The above fault tolerance requirements tends to result in the overall machine appearing oversized for its rated power. A low-speed requirement, combined with mass and space constraints and the lack of a dedicated cooling system have led the designers to consider a transverse flux machine (TFM) in this paper
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