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This paper describes the design process of a 10 kW 19000 rpm high power density surface mounted permanent magnet synchronous machine for a directly coupled pump application. In order to meet the required specifications, a compact machine, with cooling channels inside the slots and flooded airgap, has been designed through finite element optimization. For high power density, high speed machines, an accurate evaluation of the power losses and the electromechanical performance is always extremely challenging. In this case, the completely flooded application adds to the general complexity. Therefore this paper deals with a detailed losses analysis (copper, core, eddy current and mechanical losses) considering several operating conditions. The experimental measurements of AC copper losses as well as the material properties (BH curve and specific core losses), including the manufacturing process effect on the stator core, are presented. Accurate 3D finite element models and computational fluid dynamics analysis have been used to determine the eddy current losses in the rotor and windage losses respectively. Based on these detailed analysis, the no load and full load performance are evaluated. The experimental results, on the manufactured prototype, are finally presented to validate the machine design.

The constant growth of air traffic, the demand for performance optimization and the need for decreasing both operating and maintenance costs have encouraged the aircraft industry to move towards more electric solutions. As a result of this trend, electric power required on board of aircraft has significantly increased through the years, causing major changes in electric power system architectures. Considering this scenario, the paper gives a review about the evolution of electric power generation systems in aircraft. The major achievements are highlighted and the rationale behind some significant developments discussed. After a brief historical overview of the early DC generators (both wind- and engine-driven), the reasons which brought the definitive passage to the AC generation, for larger aircraft, are presented and explained. Several AC generation systems are investigated with particular attention being focused on the voltage levels and the generator technology. Further, examples of commercial aircraft implementing AC generation systems are provided. Finally, the trends towards modern generation systems are also considered giving prominence to their challenges and feasibility.

An often-overlooked aspect during the development process of electrical machines, is the validity and accuracy of the machine material properties being used at the design stage. Designers usually consider the data provided by the materials supplier, which is measured on material in an unprocessed state. However, the fact that the machining processes required to produce the finished product (e.g. the stator core) can permanently vary the material properties is very often neglected. This paper therefore deals with and investigates the effects that such processes can have on the overall machine performance. To do this, three sets of material data, based on 1) the materials suppliers’ data, 2) materials data based on conventional characterization methods and 3) materials data based on test samples that include the manufacturing processes, are used to develop three versions of the same baseline machine. The results of these three machines are then compared and the resulting variations of the machine’s performance presented and described. The chosen baseline machine is a high performance and relatively high speed, aerospace, electrical machine. Special attention is focused on the efficiency maps of the machine as this aspect is highly dependent on the material properties that are the most sensitive to manufacturing processes such as the material’s anhysteretic BH curve and its specific core loss.

Surface-mounted permanent magnet (SPM) machines are preferred for high-speed aerospace applications over induction and switched reluctance machines, since they combine the advantages of high torque density and efficiency. Also, in aerospace applications, where low rotor weight and inertia are essential requirements, a permeable hollow shaft is proposed to replace the need for rotor back-iron and reduce the overall rotor weight. For rotor mechanical integrity, a retaining sleeve is commonly used, leading to thicker magnetic airgap. Furthermore, when permeable rotor endcaps are applied, an increase of the magnetic end leakage occurs, i.e. end-effect. In this paper, the influence of the rotor endcaps on the mechanical and electromagnetic performance of a high-speed SPM machine is investigated through 3D-finite element analyses (FEA). Also, different endcap thickness and different rotor shaft materials are investigated and compared in this work. Finally, a prototype of the SPM machine under study has been manufactured and tested. The comparison between simulation and experimental results is presented and discussed.

This paper presents a newly developed Power Electronic Inverter library in Modelica. The library utilises a multi-level approach with increasing model complexity at progressively higher levels. All levels are fully interchangeable so as to provide a flexible library able to be utilised for investigation at single or multiple levels of complexity. Within this inter¬changeable multi-level approach, there are two key attributes which are implemented into this new library. The first is the ability to include losses between the input and output of the Power Electronic Inverter. This is implemented so that the losses are included irrespective of the direction of power flow. Secondly, this library also provides the ability to trigger single or multiple open and short circuit faults within the Inverter. The library therefore provides an extremely useful tool able to compare system response under a variety of operational scenarios.

High power density for aerospace motor drives is a key factor in the successful realization of the More Electric Aircraft (MEA) concept. An integrated system design approach offers optimization opportunities, which could lead to further improvements in power density. However this requires multi-disciplinary modelling and the handling of a complex optimization problem that is discrete and non¬linear in nature. This paper proposes a multi-level approach towards applying random heuristic optimization to the integrated motor design problem. Integrated optimizations are performed independently and sequentially at different levels assigned according to the 4-level modelling paradigm for electric systems. This paper also details a motor drive sizing procedure, which poses as the optimization problem to solve here. Finally, results comparing the proposed multi-level approach with a more traditional single-level approach is presented for a 2.5 kW actuator motor drive design. The multi-level approach is found to be more computationally efficient than its counterpart.

This paper introduces an innovative thermal modelling technique which accurately predicts the winding temperature of electrical machines, both at transient and steady state conditions, for applications where the stator Joule losses are the dominant heat source. The model is an advanced variation of the classical Lumped Parameter Thermal Network approach, with the expected degree of accuracy but at a much lower computational cost. A 7-node Thermal Network is first implemented and an empirical procedure to fine-tuning the critical parameters is proposed. The derivation of the low computational cost model from the Thermal Network is thoroughly explained. A simplification of the 7-node Thermal Network with an equivalent 3-node Thermal Network is then implemented, and the same procedure is applied to the new network for deriving an even faster low computational cost model. The proposed model is then validated against experimental results carried on a Permanent Magnet Synchronous Machine which is part of an electro-mechanical actuator designed for an aerospace application. A comparison between the performance of the classical Lumped Parameter Thermal Network and the proposed model is carried out, both in terms of accuracy of the stator temperature prediction and of the computational time required.

The goal of the A2015 library presented in this paper is to develop a Modelica based, tool-independent standard for electromechanical actuators (EMA). This will contribute to the establishment of a “common language” throughout the development of EMAs for aircraft and helicopters and through the supply chain. All stages of the design and validation process (conceptual design, specification, development and validation) are covered. The modeling approach addresses specific aspects of the EMA design process not covered by existing tools. The library scope, engineering need and implementation are described. Modeling of selected EMA components is discussed in more detail. An application example of the library is given (linear actuator, A320 aileron)

A high speed permanent magnet motor is designed for a flooded industrial pump. Oil in the pump is used to cool the motor. Due to the limitation of space and mass requirement for the application, thermal management is one of the main challenges. This paper describes the thermal management optimization process and design of the machine. Different cooling strategies are applied to cool the machine and Computational Fluid Dynamics (CFD) is used to predict and improve the cooling performance. The machine has been designed and is currently being manufactured.

In this paper, a novel multi-stress model which estimates the lifetime of the winding insulation relative to its duty cycle is proposed and investigated. With an adequate implementation of this model, then an electrical machine can be designed not only in terms of its performance requirements, but also considering the associated reliability and lifetime aspects. Since thermal and thermo-mechanical stresses are considered as the main ageing factors, the model is particularly suited for low voltage, low duty cycle machines. The determination of the model parameters is based on the results of accelerated thermo-mechanical ageing tests, whose procedure is thoroughly reported in the paper. The results of the accelerated ageing tests show that the effect of thermo-mechanical ageing is significant even for small size, random wound windings under fast temperature rise.

This paper presents the design optimization procedure of a high power-density, permanent magnet synchronous machine for industrial pump applications. The designed machine drives an electric, oil flooded pump. In order to achieve higher torque-density, a fractional slot machine (8 poles, 9 slots) with double layer (concentrated) winding has been selected after a preliminary trade-off study, which considered several slot/pole combinations and winding configurations. The developed machine provides low torque ripple and short end windings, which contribute to lower axial length and higher efficiency. The electromagnetic performances have been evaluated by using finite element method and the lamination geometry has been optimized through a genetic. The final results are presented highlighting the achieved design targets.

This paper presents the trade-off analysis and design of a high power-density machine for industrial pump applications. The developed permanent magnet synchronous machine drives an electric, oil flooded pump. Different slot/pole combination and winding configuration have been investigated in order to identify the optimal combination that satisfies the electromagnetic and thermal constraint while keeping the losses as small as possible. Several strategies such as the use of the Cobalt iron material for the stator core lamination and the adoption of Halbach array have been investigated in this work to improve the performance capabilities of the designed machine. The electromagnetic performances have been evaluated by using a finite element method. Thermal behaviour has been determined using a lumped parameter network. The outcome of the thermal analysis helped to identify the optimal cooling configurations. The final results are presented highlighting the achieved design targets.

In this paper, a simple and robust method for parameter estimation at rotor standstill is presented for interior permanent magnet (IPM) synchronous machines. The estimated parameters are the stator resistance through dc test, the dq inductances using high-frequency injection, and the permanent magnet flux by means of a closed-loop speed control maintaining rotor stationary. The proposed method does not require either locking the rotor or additional/special power supplies. The validity of the suggested method has been verified by implementation on two IPM motor prototypes. Finally, the estimated parameters have been compared against results obtained through finite-element simulations and with machine magnetic characterization, separately performed, to validate the method's effectiveness. Saturation and cross-saturation effects are taken care of through amplitude modulation and cross-axis current application, respectively.

Additive manufacturing is acknowledged as a key enabling technology, although its adoption is still constrained to niche applications. A promising area for this technology is the production of electrical machines (EMs) and/or their main components (e.g. magnetic cores, windings, heat exchangers, etc.) due to the potential of creating lightweight, highly efficient rotating motors, suitable for applications requiring a low moment of inertia. This work investigates the readiness of metal additive manufacturing, specifically Laser Powder Bed Fusion (LPBF), applied to the field of EMs to bridge the gaps of how to use this technological approach in this field. A soft magnetic material featuring high silicon content (Fe-5.0%w.t.Si) has been developed for LPBF and a rotor has been 3D-printed for a switched reluctance machine. The printed rotor was assembled into a conventionally laminated stator and the performance of the whole machine was evaluated. Its performance was compared against an identical machine equipped with a laminated rotor of the same dimensions made of conventional non-oriented silicon steel. A comparative study was carried out through both finite element simulations and experimental tests. The efficiency of the two machines was assessed together with the principal electrical and mechanical quantities under several operating conditions.

Estimating the lifetime of enameled wires using the conventional/standard test method requires a significant amount of time that can endure up to thousands of testing hours, which could considerably delay the time-To-market of a new product. This paper presents a new approach that estimates the insulation lifetime of enameled wire, employed in electrical machines, using curve fitting models whose computation is rapid and accurate. Three curve fit models are adopted to predict the insulation resistance of double-coated enameled magnet wire samples, with respect to their aging time. The samples' mean time-To-failure is estimated, and performance of the models is apprised through a comparison against the conventional 'standard method' of lifetime estimation of the enameled wires. The best prediction accuracy is achieved by a logarithmic curve fit approach, which gives an error of 0.95% and 1.62% when its thermal index is compared with the conventional method and manufacturer claim respectively. The proposed approach provides a time-saving of 67% (83 days) when its computation time is compared with respect to the 'standard method' of lifetime estimation.

Additive manufacturing is acknowledged as a key enabling technology, although its adoption is still constrained to niche applications. A promising area for this technology is the production of electrical machines (EMs) and/or their main components (e.g. magnetic cores, windings, heat exchangers, etc.) due to the potential of creating lightweight, highly efficient rotating motors, suitable for applications requiring a low moment of inertia. This work investigates the readiness of metal additive manufacturing, specifically Laser Powder Bed Fusion (LPBF), applied to the field of EMs to bridge the gaps of how to use this technological approach in this field. A soft magnetic material featuring high silicon content (Fe-5.0%w.t.Si) has been developed for LPBF and a rotor has been 3D-printed for a switched reluctance machine. The printed rotor was assembled into a conventionally laminated stator and the performance of the whole machine was evaluated. Its performance was compared against an identical machine equipped with a laminated rotor of the same dimensions made of conventional non-oriented silicon steel. A comparative study was carried out through both finite element simulations and experimental tests. The efficiency of the two machines was assessed together with the principal electrical and mechanical quantities under several operating conditions.

It is well known and widely accepted that the voltage source inverter (VSI) now dominates the world of electrical drives. Its success is probably due to its simplicity, high efficiency, and the widespread availability of VSs. This popularity has, in turn, influenced the evolution of the semiconductor industry, which has focused in recent years on devices tailored for VSIs. Thus, products such as depletion devices (normally off) and those without reverse voltage blocking have been widely marketed and used.

The constant growth of air traffic, the demand for performance optimization and the need for decreasing both operating and maintenance costs have encouraged the aircraft industry to move towards more electric solutions. As a result of this trend, electric power required on board of aircraft has significantly increased through the years, causing major changes in electric power system architectures. Considering this scenario, the paper gives a review about the evolution of electric power generation systems in aircraft. The major achievements are highlighted and the rationale behind some significant developments discussed. After a brief historical overview of the early DC generators (both wind- and engine-driven), the reasons which brought the definitive passage to the AC generation, for larger aircraft, are presented and explained. Several AC generation systems are investigated with particular attention being focused on the voltage levels and the generator technology. Further, examples of commercial aircraft implementing AC generation systems are provided. Finally, the trends towards modern generation systems are also considered giving prominence to their challenges and feasibility.

This paper describes the design process of a 10 kW 19000 rpm high power density surface mounted permanent magnet synchronous machine for a directly coupled pump application. In order to meet the required specifications, a compact machine, with cooling channels inside the slots and flooded airgap, has been designed through finite element optimization. For high power density, high speed machines, an accurate evaluation of the power losses and the electromechanical performance is always extremely challenging. In this case, the completely flooded application adds to the general complexity. Therefore this paper deals with a detailed losses analysis (copper, core, eddy current and mechanical losses) considering several operating conditions. The experimental measurements of AC copper losses as well as the material properties (BH curve and specific core losses), including the manufacturing process effect on the stator core, are presented. Accurate 3D finite element models and computational fluid dynamics analysis have been used to determine the eddy current losses in the rotor and windage losses respectively. Based on these detailed analysis, the no load and full load performance are evaluated. The experimental results, on the manufactured prototype, are finally presented to validate the machine design.

An often-overlooked aspect during the development process of electrical machines, is the validity and accuracy of the machine material properties being used at the design stage. Designers usually consider the data provided by the materials supplier, which is measured on material in an unprocessed state. However, the fact that the machining processes required to produce the finished product (e.g. the stator core) can permanently vary the material properties is very often neglected. This paper therefore deals with and investigates the effects that such processes can have on the overall machine performance. To do this, three sets of material data, based on 1) the materials suppliers’ data, 2) materials data based on conventional characterization methods and 3) materials data based on test samples that include the manufacturing processes, are used to develop three versions of the same baseline machine. The results of these three machines are then compared and the resulting variations of the machine’s performance presented and described. The chosen baseline machine is a high performance and relatively high speed, aerospace, electrical machine. Special attention is focused on the efficiency maps of the machine as this aspect is highly dependent on the material properties that are the most sensitive to manufacturing processes such as the material’s anhysteretic BH curve and its specific core loss.

Surface-mounted permanent magnet (SPM) machines are preferred for high-speed aerospace applications over induction and switched reluctance machines, since they combine the advantages of high torque density and efficiency. Also, in aerospace applications, where low rotor weight and inertia are essential requirements, a permeable hollow shaft is proposed to replace the need for rotor back-iron and reduce the overall rotor weight. For rotor mechanical integrity, a retaining sleeve is commonly used, leading to thicker magnetic airgap. Furthermore, when permeable rotor endcaps are applied, an increase of the magnetic end leakage occurs, i.e. end-effect. In this paper, the influence of the rotor endcaps on the mechanical and electromagnetic performance of a high-speed SPM machine is investigated through 3D-finite element analyses (FEA). Also, different endcap thickness and different rotor shaft materials are investigated and compared in this work. Finally, a prototype of the SPM machine under study has been manufactured and tested. The comparison between simulation and experimental results is presented and discussed.

High power density for aerospace motor drives is a key factor in the successful realization of the More Electric Aircraft (MEA) concept. An integrated system design approach offers optimization opportunities, which could lead to further improvements in power density. However this requires multi-disciplinary modelling and the handling of a complex optimization problem that is discrete and non¬linear in nature. This paper proposes a multi-level approach towards applying random heuristic optimization to the integrated motor design problem. Integrated optimizations are performed independently and sequentially at different levels assigned according to the 4-level modelling paradigm for electric systems. This paper also details a motor drive sizing procedure, which poses as the optimization problem to solve here. Finally, results comparing the proposed multi-level approach with a more traditional single-level approach is presented for a 2.5 kW actuator motor drive design. The multi-level approach is found to be more computationally efficient than its counterpart.

The goal of the A2015 library presented in this paper is to develop a Modelica based, tool-independent standard for electromechanical actuators (EMA). This will contribute to the establishment of a “common language” throughout the development of EMAs for aircraft and helicopters and through the supply chain. All stages of the design and validation process (conceptual design, specification, development and validation) are covered. The modeling approach addresses specific aspects of the EMA design process not covered by existing tools. The library scope, engineering need and implementation are described. Modeling of selected EMA components is discussed in more detail. An application example of the library is given (linear actuator, A320 aileron)

This paper presents a newly developed Power Electronic Inverter library in Modelica. The library utilises a multi-level approach with increasing model complexity at progressively higher levels. All levels are fully interchangeable so as to provide a flexible library able to be utilised for investigation at single or multiple levels of complexity. Within this inter¬changeable multi-level approach, there are two key attributes which are implemented into this new library. The first is the ability to include losses between the input and output of the Power Electronic Inverter. This is implemented so that the losses are included irrespective of the direction of power flow. Secondly, this library also provides the ability to trigger single or multiple open and short circuit faults within the Inverter. The library therefore provides an extremely useful tool able to compare system response under a variety of operational scenarios.

This paper introduces an innovative thermal modelling technique which accurately predicts the winding temperature of electrical machines, both at transient and steady state conditions, for applications where the stator Joule losses are the dominant heat source. The model is an advanced variation of the classical Lumped Parameter Thermal Network approach, with the expected degree of accuracy but at a much lower computational cost. A 7-node Thermal Network is first implemented and an empirical procedure to fine-tuning the critical parameters is proposed. The derivation of the low computational cost model from the Thermal Network is thoroughly explained. A simplification of the 7-node Thermal Network with an equivalent 3-node Thermal Network is then implemented, and the same procedure is applied to the new network for deriving an even faster low computational cost model. The proposed model is then validated against experimental results carried on a Permanent Magnet Synchronous Machine which is part of an electro-mechanical actuator designed for an aerospace application. A comparison between the performance of the classical Lumped Parameter Thermal Network and the proposed model is carried out, both in terms of accuracy of the stator temperature prediction and of the computational time required.

A high speed permanent magnet motor is designed for a flooded industrial pump. Oil in the pump is used to cool the motor. Due to the limitation of space and mass requirement for the application, thermal management is one of the main challenges. This paper describes the thermal management optimization process and design of the machine. Different cooling strategies are applied to cool the machine and Computational Fluid Dynamics (CFD) is used to predict and improve the cooling performance. The machine has been designed and is currently being manufactured.

In this paper, a novel multi-stress model which estimates the lifetime of the winding insulation relative to its duty cycle is proposed and investigated. With an adequate implementation of this model, then an electrical machine can be designed not only in terms of its performance requirements, but also considering the associated reliability and lifetime aspects. Since thermal and thermo-mechanical stresses are considered as the main ageing factors, the model is particularly suited for low voltage, low duty cycle machines. The determination of the model parameters is based on the results of accelerated thermo-mechanical ageing tests, whose procedure is thoroughly reported in the paper. The results of the accelerated ageing tests show that the effect of thermo-mechanical ageing is significant even for small size, random wound windings under fast temperature rise.

In this paper, a simple and robust method for parameter estimation at rotor standstill is presented for interior permanent magnet (IPM) synchronous machines. The estimated parameters are the stator resistance through dc test, the dq inductances using high-frequency injection, and the permanent magnet flux by means of a closed-loop speed control maintaining rotor stationary. The proposed method does not require either locking the rotor or additional/special power supplies. The validity of the suggested method has been verified by implementation on two IPM motor prototypes. Finally, the estimated parameters have been compared against results obtained through finite-element simulations and with machine magnetic characterization, separately performed, to validate the method's effectiveness. Saturation and cross-saturation effects are taken care of through amplitude modulation and cross-axis current application, respectively.

Estimating the lifetime of enameled wires using the conventional/standard test method requires a significant amount of time that can endure up to thousands of testing hours, which could considerably delay the time-To-market of a new product. This paper presents a new approach that estimates the insulation lifetime of enameled wire, employed in electrical machines, using curve fitting models whose computation is rapid and accurate. Three curve fit models are adopted to predict the insulation resistance of double-coated enameled magnet wire samples, with respect to their aging time. The samples' mean time-To-failure is estimated, and performance of the models is apprised through a comparison against the conventional 'standard method' of lifetime estimation of the enameled wires. The best prediction accuracy is achieved by a logarithmic curve fit approach, which gives an error of 0.95% and 1.62% when its thermal index is compared with the conventional method and manufacturer claim respectively. The proposed approach provides a time-saving of 67% (83 days) when its computation time is compared with respect to the 'standard method' of lifetime estimation.

This paper presents the trade-off analysis and design of a high power-density machine for industrial pump applications. The developed permanent magnet synchronous machine drives an electric, oil flooded pump. Different slot/pole combination and winding configuration have been investigated in order to identify the optimal combination that satisfies the electromagnetic and thermal constraint while keeping the losses as small as possible. Several strategies such as the use of the Cobalt iron material for the stator core lamination and the adoption of Halbach array have been investigated in this work to improve the performance capabilities of the designed machine. The electromagnetic performances have been evaluated by using a finite element method. Thermal behaviour has been determined using a lumped parameter network. The outcome of the thermal analysis helped to identify the optimal cooling configurations. The final results are presented highlighting the achieved design targets.

This paper presents the design optimization procedure of a high power-density, permanent magnet synchronous machine for industrial pump applications. The designed machine drives an electric, oil flooded pump. In order to achieve higher torque-density, a fractional slot machine (8 poles, 9 slots) with double layer (concentrated) winding has been selected after a preliminary trade-off study, which considered several slot/pole combinations and winding configurations. The developed machine provides low torque ripple and short end windings, which contribute to lower axial length and higher efficiency. The electromagnetic performances have been evaluated by using finite element method and the lamination geometry has been optimized through a genetic. The final results are presented highlighting the achieved design targets.

It is well known and widely accepted that the voltage source inverter (VSI) now dominates the world of electrical drives. Its success is probably due to its simplicity, high efficiency, and the widespread availability of VSs. This popularity has, in turn, influenced the evolution of the semiconductor industry, which has focused in recent years on devices tailored for VSIs. Thus, products such as depletion devices (normally off) and those without reverse voltage blocking have been widely marketed and used.

This paper describes the design process of a 10 kW 19000 rpm high power density surface mounted permanent magnet synchronous machine for a directly coupled pump application. In order to meet the required specifications, a compact machine, with cooling channels inside the slots and flooded airgap, has been designed through finite element optimization. For high power density, high speed machines, an accurate evaluation of the power losses and the electromechanical performance is always extremely challenging. In this case, the completely flooded application adds to the general complexity. Therefore this paper deals with a detailed losses analysis (copper, core, eddy current and mechanical losses) considering several operating conditions. The experimental measurements of AC copper losses as well as the material properties (BH curve and specific core losses), including the manufacturing process effect on the stator core, are presented. Accurate 3D finite element models and computational fluid dynamics analysis have been used to determine the eddy current losses in the rotor and windage losses respectively. Based on these detailed analysis, the no load and full load performance are evaluated. The experimental results, on the manufactured prototype, are finally presented to validate the machine design.