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Design of an aircraft generator with radial force control.

With the increasing electrical energy demands in aviation propulsion systems, the increase in the onboard generators' power density is inevitable. During the flight, forces coming from the gearbox or gyroscopic forces generated by flight manoeuvres like take-off and landing can act on the generators' bearings, which can lead to wear and fatigue in the bearings. Utilizing the radial force control concept in the electrical machine can relieve loads from the bearings that not only minimize the bearing losses but also increase bearing life. The objective of the MAGLEV project (Measurement and Analysis of Generator bearing Loads and Efficiency with Validation) is to study, demonstrate, and test a new class of high-speed generators with radial force control. In this paper, design steps of this type of generator and its test rig are presented and the measurement methodology used for radial force control is explained. The concept is developed in an electrical machine and is validated on a test rig by measuring required parameters like shaft displacement, vibrations and bearing temperature. Additionally, the friction moment of each generator's bearings is measured and validated in a separate test rig under comparable conditions to the bearing loads in the generator. Therefore, a novel approach to determine precisely the bearing friction in a radial load unit, rotatably supported by an additional needle bearing is used, which shows a good agreement with the calculated friction. Furthermore, new calculation methods for the operating behavior of cylindrical roller bearings with clearance are presented, which are utilized in the generator test rig.

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Adaptive Finite Element Simulation of Double-Diffusive Convection

Double-diffusive convection plays an important role in many physical phenomena of practical importance. However, the numerical simulation of these phenomena is challenging since fine meshes are often required to capture the flow physics. Hence, several different numerical methods have been employed in the past. This work reports the development and application of an adaptive finite element method for the simulation of these phenomena, thereby avoiding the need for the use of very fine meshes over the whole domain. The weak formulation of the conservation equations for mass, momentum, energy and species concentration is used. The Boussinesq approximation relates the density of the fluid to the temperature and/or the species concentration. A second-order backward difference method is used for time discretization and the Galerkin method is employed for spatial discretization. Both adaptive time step and grid refinement techniques are employed, and the code is parallelized using MPI. Three different stabilization methods of the convective-diffusion equations are compared; namely, the streamline upwind Petrov–Galerkin (SUPG) method, and two modified methods aimed at diminishing spurious oscillations that include an artificial diffusion term. This diffusion term may be either isotropic or orthogonal to the streamlines. The addition of artificial isotropic diffusion to the SUPG method provides enhanced stability. The method is applied to double-diffusive finger convection in a sucrose-salt aqueous mixture and a stratified salt solution heated from below. The method accurately reproduces the experimentally observed temporal evolution of the salt fingers in the former case and the location of the interfaces between convective and non-convective zones in the latter.

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Performance analysis of a hybrid ferrite IPM/SynR traction machine with axially combined rotor structure

The paper presents the performance analysis of a hybrid Ferrite Interior Permanent Magnet (IPM)/synchronous reluctance (SynR) traction machine with axially combined rotor structure. First, a hybrid rotor with axially combined structure of Ferrite IPM rotor and SynR rotor is introduced. Then, performance analysis is presented. It is shown that due to the axially combined structure, the hybrid concept machine could achieve a significant lower copper and iron loss in the high-speed operation region, compared with the original Ferrite IPM machine. It is demonstrated that due to the difference in optimum operation between the IPM and SynR machines, the two-rotor parts could be circumferentially shifted by an optimum angle for a specific control target achievement, i.e., maximum torque per amper (MTPA) or minimum energy consumption over a specific driving cycle. Therefore, an extra degree of freedom on design could be obtained for the hybrid rotor structure. The proposed concept is validated via FEA benchmarking by a high-speed high-power (12,000rpm and 80kW) Ferrite IPM traction machine. It is shown that in comparison with the Ferrite IPM machine, a reduction up to 26.29% in energy consumption over WLTP driving cycle could be achieved for the proposed hybrid rotor concept machine.

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Modular Power Sharing Control for Bearingless Multithree Phase Permanent Magnet Synchronous Machine

This article proposes a modular approachto the power sharing control of permanent magnet synchronous bearingless machine. The selected machine topology features a winding layout with phases distributed into nonoverlapping three phase groups, a solution whose twofold aim is to increase the fault tolerance and to allow for the radial force generation. The three phase subwindings are supplied by standard three-phase inverter, leading to a modular system architecture. A throughout explanation of the methodology used to develop the control algorithm is presented considering the torque and force control in combination with the power sharing management of the machine. Special emphasis is placed on validating the modeling hypotheses based on a finite element characterization of the machine electro-mechanical behavior. The proposed control strategy is also extended to cater the possibility of one or more inverters failure, thus validating the intrinsic advantage of the redundancy obtained by the modularity of the system. An extensive experimental test campaign is finally carried out on a prototyped multi three-phase permanent magnet synchronous drive. The obtained results validate the bearingless power sharing operation in healthy and faulty scenarios, both at steady state and under extreme transient condition.

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Design of an aircraft generator with radial force control

With the increasing electrical energy demands in aviation propulsion systems, the increase in the onboard generators’ power density is inevitable. During the flight, forces coming from the gearbox or gyroscopic forces generated by flight manoeuvres like take-off and landing can act on the generators' bearings, which can lead to wear and fatigue in the bearings. Utilizing the radial force control concept in the electrical machine can relieve loads from the bearings that not only minimize the bearing losses but also increase bearing life. The objective of the MAGLEV project (Measurement and Analysis of Generator bearing Loads and Efficiency with Validation) is to study, demonstrate, and test a new class of high-speed generators with radial force control. In this paper, design steps of this type of generator and its test rig are presented and the measurement methodology used for radial force control is explained. The concept is developed in an electrical machine and is validated on a test rig by measuring required parameters like shaft displacement, vibrations and bearing temperature. Additionally, the friction moment of each generator’s bearings is measured and validated in a separate test rig under comparable conditions to the bearing loads in the generator. Therefore, a novel approach to determine precisely the bearing friction in a radial load unit, rotatably supported by an additional needle bearing is used, which shows a good agreement with the calculated friction. Furthermore, new calculation methods for the operating behavior of cylindrical roller bearings with clearance are presented, which are utilized in the generator test rig.

Read full abstract
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