Skip to main content Accessibility help

We use cookies to distinguish you from other users and to provide you with a better experience on our websites. Close this message to accept cookies or find out how to manage your cookie settings.

Close cookie message
×
Hostname: page-component-586b7cd67f-2plfb Total loading time: 0 Render date: 2024-11-24T09:48:26.286Z Has data issue: false hasContentIssue false

3 - Megawatt-Scale Electric Machines for Electrified Aircraft Propulsion

Published online by Cambridge University Press:  11 May 2022

By
Tim C. O’Connell  and
Xiaolong Zhang
Edited by
Kiruba Haran ,
Nateri Madavan  and
Tim C. O'Connell
Kiruba Haran
Affiliation:
University of Illinois, Urbana-Champaign
Nateri Madavan
Affiliation:
NASA Aeronautics Mission Directorate, NASA
Tim C. O'Connell
Affiliation:
P.C. Krause & Associates
Get access

Summary

This chapter identifies the specifications of megawatt (MW)-scale electric machines (EMs) that facilitate electrified aircraft propulsion (EAP). Because their specific power (SP) must increase by an order of magnitude over the current state-of-the-art (SOTA), a review of conventional EMs for EAP is presented, focusing on approaches for mass reduction and SP increase. Design challenges associated with high specific power (HSP) MW-scale machines are identified, and a review of EAP powertrain architectures and how HSP EMs enable them is provided. Next follows a description focused on propulsion motors, high speed generators, and system considerations unique to the EAP powertrain. Design principles for high power, lightweight, MW-scale EM development are discussed, and a comprehensive survey of over 50 SOTA HSP machines is presented. Common HSP machine features are identified and promising options for further weight reduction are discussed. Despite their SOTA classification, the surveyed machines fall well short of the lofty requirements necessary for next generation components, and some emerging technologies that may help to remedy these shortcomings are described.

Keywords

megawatt-scale electric machinehigh specific powerelectric machine classificationpropulsion motorhigh-speed generatorsizing equationelectromagnetic loadingcooling systemhigh speed indexpower scaling
Type
Chapter
Information
Electrified Aircraft Propulsion
Powering the Future of Air Transportation
 , pp. 49 - 87
Publisher: Cambridge University Press
Print publication year: 2022

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

Zhang, X., Bowman, C. L., O’Connell, T. C., and Haran, K., “Large electric machines for aircraft electric propulsion,” IET Electr. Power Appl., vol. 12, pp. 767–779, 2018.Google Scholar
Haran, K. et al., “High power density superconducting rotating machines–development status and technology roadmap,” Supercond. Sci. Technol., vol. 30, pp. 1–41, 2017.Google Scholar
National Academies of Sciences, Engineering, and Medicine, Commercial Aircraft Propulsion and Energy Systems Research: Reducing Global Carbon Emissions, Washington, DC: National Academy Press, 2016.Google Scholar
Marathon Motors, Wausau, WI, USA. “Product Catalog: Commercial and Industrial SB300.” (2014). Accessed: December 20, 2018. [Online]. Available: www.regalbeloit.com/-/media/Files/Literature/Marathon-Motors-Literature/SB300MarathonCatalog2014.pdf.Google Scholar
Remy Electric Motors, Pendleton, IN, USA. “REMY HVH410–075-DOM Electric Motor Brochure.” (2011). Accessed: December 20, 2018. [Online]. Available: https://cdn.borgwarner.com/docs/default-source/default-document-library/remy-pds---hvh410–075-sheet-euro-pr-3-16.pdf?sfvrsn=a742cd3c_13.Google Scholar
Siemens AG, Munich, Germany. “Siemens Develops World-Record Electric Motor for Aircraft.” (2015). Accessed: December 20, 2018. [Online]. Available: www.siemens.com/press/PR2015030156COEN.Google Scholar
Yoon, A. et al., “A high-speed, high-frequency, air-core PM machine for aircraft application,” presented at the IEEE Power and Energy Conf. at Illinois, Urbana, IL, 2016.Google Scholar
Jansen, R. et al., “Overview of NASA electrified aircraft propulsion research for large subsonic transports,” presented at the 53rd AIAA/SAE/ASEE Joint Propulsion Conf., Atlanta, GA, 2017, Paper AIAA 2017-4701.Google Scholar
Huang, S. et al., “A general approach to sizing and power density equations for comparison of electric machines,” IEEE Trans. Ind. Appl., vol. 34, pp. 92–97, 1998.Google Scholar
Huang, S. et al., “A comparison of power density for axial flux machines based on general purpose sizing equations,” IEEE Trans. Energy Convers., vol. 14 pp. 185–192, 1999.CrossRefGoogle Scholar
Qu, R. and Lipo, T. A., “Sizing equations and power density evaluation of dual-rotor, radial flux, toroidally-wound, permanent-magnet machines,” presented at the IEEE 16th Int. Conf. on Electr. Mach., Cracow, Poland, 2004.Google Scholar
Felder, J. L., “NASA electric propulsion system studies,” NASA, Cleveland, OH, Tech. Rep. GRC-EDAA-TN28410, 2015.Google Scholar
Lents, C. E. et al., “Parallel hybrid gas-electric geared turbofan engine conceptual design and benefits analysis,” presented at the 52nd AIAA/SAE/ASEE Joint Propulsion Conf., Salt Lake City, UT, 2016, Paper AIAA 2016-4610.CrossRefGoogle Scholar
Trawick, D. et al., “Development and application of GT-HEAT for the electrically variable engine(™) design,” presented at the 55th AIAA Aerosp. Sci. Mtg., Grapevine, TX, 2017, Paper AIAA 2017-1922.CrossRefGoogle Scholar
Ganev, E., “Selecting the best electric machines for electrical power-generation systems: High-performance solutions for aerospace more electric architectures,” IEEE Electrif. Mag., pp. 13–22, December 2014.Google Scholar
Lipo, T. A., Introduction to AC Machine Design. Hoboken, NJ: IEEE Press/Wiley, 2017.CrossRefGoogle Scholar
Adkins, B. and Harley, R. G., The General Theory of Alternating Current Machines: Application to Practical Problems, New York, NY: Halsted, 1975.Google Scholar
Alger, P. L., Induction Machines: Their Behavior and Uses, 2nd ed., New York, NY: Gordon and Breach, 1995.Google Scholar
Popescu, M. et al., “Modern heat extraction systems for electrical machines: A review,” in Proc. 2015 IEEE Workshop on Elect. Mach. Design, Control and Diagnosis, Torino, Italy, 2015, pp. 289–296.Google Scholar
Tong, W., “Motor cooling,” in Mechanical Design of Electric Motors, 1st ed., Boca Raton, FL: CRC Press, 2014, ch. 8.CrossRefGoogle Scholar
Gieras, J. F., “High power density machines,” in Advancements in Electric Machines, New York, NY: Springer-Verlag, 2008, ch. 3, pp. 71–80.Google Scholar
El-Refaie, A. M., “Fractional-slot concentrated-windings synchronous permanent magnet machines: Opportunities and challenges,” IEEE Trans. Ind. Electron., vol. 57, pp. 107–121, 2010.Google Scholar
Rahman, M. A., Chiba, A., and Fukao, T., “Super high speed electrical machines: Summary,” in Proc. IEEE Power Eng. Soc. General Mtg., Denver, CO, 2004, pp. 1268–1271.Google Scholar
Gerada, D. et al., “High-speed electric machines: technologies, trends, and developments,” IEEE Trans. Ind. Electron., vol. 61, pp. 2946–2959, 2014.Google Scholar
Tenconi, A., Vaschetto, S., and Vigliani, A., “Electric machines for high-speed applications: Design considerations and tradeoffs,” IEEE Trans. Ind. Electron., vol. 61, pp. 3022–3029, 2014.Google Scholar
Binder, A. and Schneider, T., “High-speed inverter-fed AC drives,” in Proc. IEEE Int. Aegean Conf. on Elect. Mach. and Power Elect., Bodrum, Turkey, 2007, pp. 9–16.Google Scholar
Borisavljevic, A., Polinder, H., and Ferreira, J. A., “On the speed limits of permanent-magnet machines,” IEEE Trans. Ind. Electron., vol. 57, pp. 220–227, 2010.Google Scholar
Moghaddam, R. R., “High speed operation of electrical machines, a review on technology, benefits and challenges,” in Proc. IEEE Energy Convers. Congr. and Expo., Pittsburgh, PA, 2014, pp. 5539–5546.Google Scholar
van Millingen, R. D. and van Millingen, J. D., “Phase shift torquemeters for gas turbine development and monitoring,” in Proc. ASME Int. Gas Turbine and Aeroengine Congr. and Expo., Orlando, FL, 1991, pp. 1–10.Google Scholar
Yi, X., Yoon, A., and Haran, K. S., “Multi-physics optimization for high-frequency air-core permanent-magnet motor of aircraft application,” in Proc. IEEE Int. Elect. Mach. and Drives Conf., Miami, FL, 2017, pp. 1–8.Google Scholar
Jahns, T. M., “The expanding role of PM machines in direct-drive applications,” in 2011 Proc. IEEE Int. Conf. on Elect. Mach. and Syst., Beijing, China, 2011, pp. 1–6.Google Scholar
ThinGap, Camarillo, CA, “Products: TG-Series Motors.”Accessed: December 20, 2018. [Online]. thingap.com. www.thingap.com/standard-products/.Google Scholar
Joby Motors, Santa Cruz, CA, “Joby JM1 and JM1S electric aircraft propulsion motors.Accessed: June 2017. [Online]. ” jobymotors.com. www.jobymotors.com/public/views/pages/products.php.Google Scholar
Mekhiche, M. et al., “High speed motor drive development for industrial applications,” in Proc. IEEE Int. Conf. Electr. Mach. and Drives, Seattle, WA, 1999, pp. 244–248.Google Scholar
Munteanu, G. et al., “No-load tests of a 40 kW high-speed bearingless permanent magnet synchronous motor,” in Proc. IEEE Int. Symp. Power Electr., Electr. Drives, Automation and Motion, Pisa, Italy, 2010, pp. 1460–1465.Google Scholar
Zheng, L. et al., “Design of a superhigh-speed cryogenic permanent magnet synchronous motor,” IEEE Trans. Magn., vol. 41, pp. 3823–3825, 2005.Google Scholar
Acharya, D. et al., “Systems design, fabrication, and testing of a high-speed miniature motor for cryogenic cooler,” Int. J. Rotating Mach., vol. 2009, pp. 1–9, 2009.CrossRefGoogle Scholar
Mecrow, B. C. et al., “Design and testing of a four-phase fault-tolerant permanent-magnet machine for an engine fuel pump,” IEEE Trans. Energy Convers., vol. 19, pp. 671–678, 2004.Google Scholar
Atkinson, G. J. et al., “The analysis of losses in high-power fault-tolerant machines for aerospace applications,” IEEE Trans. Ind. Appl., vol. 42, pp. 1162–1170, 2006.CrossRefGoogle Scholar
Gieras, J. F., Wang, R. -J., and Kamper, M. J., Axial Flux Permanent Magnet Brushless Machines, New York, NY: Springer-Verlag, 2008.Google Scholar
EMRAX Innovative E-Motors, Kamnik, Slovenia, “EMRAX 208 and 228 electric motor technical specifications.” emrax.com. emrax.com/products.html.Google Scholar
YASA, Kidlington, UK, “YASA standard products technical specifications.” Accessed: December 20, 2018. [Online]. yasa.com. www.yasamotors.com/products.Google Scholar
AVID Technology, Northumberland, U.K. “EVO axial flux electric motors.” Accessed: December 20, 2018. [Online]. avidtp.com. https://avidtp.com/product/evo-motors.Google Scholar
Long, G., “High efficiency, high power density electric motors.”Accessed: December 20, 2018. [Online]. http://cafefoundation.org/v2/pdf_tech/MPG.engines/HE_HP_electric_motors_Long_20090929.pdf.Google Scholar
Sanchez, R. et al., “Mechanical validation of a high power density external cantilevered rotor,” IEEE Trans. Ind. Appl., vol. 54, pp. 3208–3216, 2018.Google Scholar
Renner, N. J. et al., “Development of form-wound air-core armature windings for high-frequency electric machines,” in Proc. IEEE Int. Elect. Mach. and Drives Conf., Miami, FL, 2017, pp. 1–8.Google Scholar
Soong, W. L. et al., “Novel high-speed induction motor for a commercial centrifugal compressor,” IEEE Trans. Ind. Appl., vol. 36, pp. 706–713, 2000.Google Scholar
Gieras, J. F. and Saari, J., “Performance calculation for a high-speed solid-rotor induction motor,” IEEE Trans. Ind. Electron., vol. 59, pp. 2689–2700, 2012.Google Scholar
Pyrhönen, J. et al., “High-speed high-output solid-rotor induction-motor technology for gas compression,” IEEE Trans. Ind. Electron., vol. 57 pp. 272–280, 2010.Google Scholar
Pyrhönen, J. et al., “High-speed, 8 MW, solid-rotor induction motor for gas compression,” in Proc. 18th IEEE Int. Conf. on Elect. Mach., Vilamoura, Portugal, 2008, pp. 1–6.Google Scholar
O’Connell, T. C., Wells, J. R., and Watts, O. A., “A lumped parameter off-axis-capable dynamic switched reluctance machine model including unbalanced radial forces,” IEEE Trans. Energy Convers., vol. 30, pp. 161–174, 2015.Google Scholar
Gieras, J. F., “Multimegawatt synchronous generators for airborne applications: A review,” in 2013 Proc. IEEE Int. Elect. Mach. and Drives Conf., Chicago, IL, 2013, pp. 626–633.Google Scholar
Burress, T. A. et al., “Evaluation of the 2010 Toyota Prius hybrid synergy drive system,” Oak Ridge National Lab., Oak Ridge, TN, Tech. Rep. ORNL/TM-2010/253, 2011.Google Scholar
Bowman, R., private communication, March 2014.Google Scholar
Zhang, X. and Haran, K. S., “High-specific-power electric machines for electrified transportation applications-technology options,” in 2016 Proc. IEEE Energy Convers. Congr. and Expo., Milwaukee, WI, 2016, pp. 1–8.Google Scholar
GreatPlanes, Champaign, IL, “Rimfire Outrunner Brushless Motors (GPM4805).” Accessed: December 20, 2018. [Online]. greatplanes.com. www.greatplanes.com/motors/gpmg4505.php.Google Scholar
Lange Aviation, Zweibrucken, Germany, “Antares 23E Technical Data.” Accessed: December 20, 2018. [Online]. lange-aviation.com. www.lange-aviation.com/en/produkte/antares-23et/techn-daten/.Google Scholar
Sineton Research and Development, Maribor, Slovenia, “Electric Motor A30K016. Accessed: December 20, 2018. [Online].” sineton.com. www.sineton.com/web/index-9.html.Google Scholar
Remy Electric Motors, Pendleton, IN, USA. “REMY HVH250–115-DOM Electric Motor Brochure.” (2011). Accessed: December 20, 2018. [Online]. Available: https://cdn.borgwarner.com/docs/default-source/default-document-library/remy-pds---hvh250–115-sheet-euro-pr-3-16.pdf?sfvrsn=ad42cd3c_11.Google Scholar
Grotendorst, J., “Hannover Messe 2013 Preliminary Press Conference: Expert Talk.Accessed: December 20, 2018. [Online].” siemens.com. www.siemens.com/press/pool/de/events/2013/industry/2013-03-hannovermesse-pk/expert-talk-inside-e-car-e.pdf.Google Scholar
Wang, Y. et al., “Design and experimental verification of high power density interior permanent magnet motors for underwater propulsions.” in Proc. IEEE Int. Conf. Elect. Mach. and Syst., Beijing, China, 2011, pp. 1–6.Google Scholar
Kosaka, T. et al., “Experimental drive performance evaluation of high power density wound field flux switching motor for automotive applications,” in Proc. IET 7th Int. Conf. Power Electron., Mach., and Drives, Manchester, UK, 2014, pp. 1–6.Google Scholar
Raimondi, G. M. et al., “Aircraft embedded generation systems,” in Proc. IET Int. Conf. Power Electron., Mach., and Drives, Santa Fe, NM, 2002, pp. 217–222.Google Scholar
Kim, S.-I. et al., “A novel rotor configuration and experimental verification of interior PM synchronous motor for high-speed applications,” IEEE Trans. Magn., vol. 48, pp. 843–846, 2012.Google Scholar
Kuznetsov, S., “Machine design and configuration of a 7000 HP hybrid electric drive for naval ship propulsion,” in Proc. IEEE Int. Elect. Mach. and Drives Conf., Niagara Falls, ON, Canada, 2011, pp. 1625–1628.Google Scholar
Maxx Products International, LLC, Lake Zurich, IL. “HIMAX Brushless Motors, 500 W and Up.” (2018). Accessed December 20, 2018. [Online]. Available: www.maxxprod.com/mpi/mpi-2601.htmlGoogle Scholar
Haylock, J. A. et al., “Operation of a fault tolerant PM drive for an aerospace fuel pump application,” IEE Proc. Elect. Power Appl., vol. 145, pp. 441–448, 1998.CrossRefGoogle Scholar
LaunchPoint Technologies, Goleta, CA, “Electric Machines for Propulsion.” Accessed: December 20, 2018. [Online]. launchpnt.com. www.launchpnt.com/portfolio/aerospace/hybrid-electric-uav-motors.Google Scholar
Crescimbini, F. et al., “Compact permanent-magnet generator for hybrid vehicle applications,” IEEE Trans. Ind. Appl., vol. 41, pp. 1168–1177, 2005.CrossRefGoogle Scholar
Caricchi, F. et al., “Axial-flux permanent-magnet generator for induction heating gensets,” IEEE Trans. Ind. Electron., vol. 57, pp. 128–137, 2010.Google Scholar
Miura, T. et al., “A ferrite permanent magnet axial gap motor with segmented rotor structure for the next generation hybrid vehicle,” in Proc. IEEE 19th Int. Conf. Elect. Mach., Rome, Italy, 2010, pp. 1–6.Google Scholar
Chino, S. et al., “Fundamental characteristics of a ferrite permanent magnet axial gap motor with segmented rotor structure for the hybrid electric vehicle,” in Proc. 3rd IEEE Energy Convers. Congr. and Expo, Phoenix, AZ, 2011, pp. 2805–2811.Google Scholar
Thelen, R. F. et al., “A 2-MW motor and ARCP drive for high-speed flywheel,” in Proc. 22nd IEEE Appl. Power Electron. Conf. and Expo., Anaheim, CA, 2007, pp. 1690–1694.Google Scholar
Kim, Y.-K. et al., “High-speed induction motor development for small centrifugal compressor,” in Proc. Fifth Int. Conf. on Elect. Mach. and Syst., Shenyang, China, 2001, pp. 891–894.Google Scholar
Gessese, Y. and Binder, A., “Axially slitted, high-speed solid-rotor induction motor technology with copper end-rings,” in 2009 Proc. IEEE Int. Conf. Elect. Mach. and Syst., Tokyo, Japan, 2009, pp. 1–6.Google Scholar
Gessese, Y., Binder, A., and Funieru, B., “Analysis of the effect of radial rotor surface grooves on rotor losses of high speed solid rotor induction motor,” in 2010 Proc. IEEE Int. Symp. Power Electr., Electr. Drives, Automation and Motion, Pisa, Italy, 2010, pp. 1762–1767.Google Scholar
Hofmann, H. and Sanders, S. R., “High-speed synchronous reluctance machine with minimized rotor losses,” IEEE Trans. Ind. Appl., vol. 36, pp. 531–539, 2000.Google Scholar
MacMinn, S. R. and Jones, W. D., “A very high speed switched-reluctance starter-generator for aircraft engine applications,” in Proc. IEEE Nat. Aerosp. and Electron. Conf., Dayton, OH, 1989, pp. 1758–1764.Google Scholar
Radun, A. V., “High power density switched reluctance motor drive for aerospace applications,” in Conf. Rec. IEEE Ind. Applicat. Soc. Annu. Mtg., San Diego, CA, 1989, pp. 568–573.Google Scholar
Ferreira, C. A. et al., “Design and implementation of a five-hp, switched reluctance, fuel-lube, pump motor drive for a gas turbine engine,” IEEE Trans. Power Electron., vol. 10, pp. 55–61, 1995.Google Scholar
Ferreira, C. A. et al., “Detailed design of a 30-kW switched reluctance starter/generator system for a gas turbine engine application,” IEEE Trans. Ind. Appl., vol. 31, pp. 553–561, 1995.Google Scholar
Ferreira, C. A., Jones, S. R., and Heglund, W. S., “Performance evaluation of a switched reluctance starter/generator system under constant power and capacitive type loads,” in 1995 Proc. IEEE Appl. Power Electron. Conf. and Expo., Dallas, TX, 1995, pp. 416–424.Google Scholar
Richter, E. and Ferreira, C., “Performance evaluation of a 250 kW switched reluctance starter generator” in Conf. Rec. 1995 IEEE Ind. Applic. Soc. Annu. Mtg., Orlando, FL, 1995, pp. 434–440.Google Scholar
Radun, A. V., Ferreira, C. A., and Richter, E., “Two-channel switched reluctance starter/generator results,” IEEE Trans. Ind. Appl., vol. 34, pp. 1026–1034, 1998.Google Scholar
Garrigan, N. R. et al., “Radial force characteristics of a switched reluctance machine,” in Conf. Rec. 1999 IEEE Ind. Applic. Soc. Annu. Mtg., Phoenix, AZ, 1999, pp. 2250–2258.Google Scholar
Hammond, E. F., Neff, W. S., and Shilling, W. J., “A 2.5-MVA high-voltage lightweight generator.,” J. Aircr., vol. 16, pp. 55–61, 1979.Google Scholar
van der Geest, M. et al., “Power density limits and design trends of high-speed permanent magnet synchronous machines,” IEEE Trans. Transport. Electrif., vo. 1, pp. 266–276, 2015.Google Scholar
Madavan, N. et al., “A NASA perspective on electric propulsion technologies for commercial aviation,” presented at the Grainger CEME/IEEE Workshop on Technology Roadmap for Large Elect. Mach., Urbana, IL, 2016.Google Scholar

Save book to Kindle

To save this book to your Kindle, first ensure [email protected] is added to your Approved Personal Document E-mail List under your Personal Document Settings on the Manage Your Content and Devices page of your Amazon account. Then enter the ‘name’ part of your Kindle email address below. Find out more about saving to your Kindle.

Note you can select to save to either the @free.kindle.com or @kindle.com variations. ‘@free.kindle.com’ emails are free but can only be saved to your device when it is connected to wi-fi. ‘@kindle.com’ emails can be delivered even when you are not connected to wi-fi, but note that service fees apply.

Find out more about the Kindle Personal Document Service.

Available formats
×

Save book to Dropbox

To save content items to your account, please confirm that you agree to abide by our usage policies. If this is the first time you use this feature, you will be asked to authorise Cambridge Core to connect with your account. Find out more about saving content to Dropbox.

Available formats
×

Save book to Google Drive

To save content items to your account, please confirm that you agree to abide by our usage policies. If this is the first time you use this feature, you will be asked to authorise Cambridge Core to connect with your account. Find out more about saving content to Google Drive.

Available formats
×