The Navy seeks to develop new, innovative motor/generator technologies that can effectively operate at speeds up to 1,000 kRPM at power densities of 40 kW/kg (excluding heat exchanger) with an overall system efficiency of 95% or better. Such a motor/generator will have a wide range of applications, i.e. it can be used as the core building block of a very lightweight electrical energy storage system for unmanned aerial vehicles (UAV) or to maintain power quality in micro-grids that experience high pulse loads such as airframes and Navy ships. We have identified that it is feasible in principle to build a 500 kW motor/generator operating above 750 kRPM using emerging technologies and materials. In our preliminary analysis we have identified several technologies and projected their respective performance. Technical risk factors and technical unknowns have been identified along with potential solutions. This framework will guide us in our Phase I analysis which is aimed to provide a more in depth analysis along with simulations and inputs from consultants to confirm the feasibility to build such a machine in Phase II with a reasonable promise of success. The research will be performed jointly with the University of Wisconsin and the University of Virginia.
Benefit: The proposed research has many tangible benefits and, more importantly, commercial and military applications. Studies have shown that rotating energy storage systems can surpass the power and weight density of the battery and capacitive storage systems at rotational speeds of 250 kRPM to 350 kRPM. This gives motor/generator energy storage systems many immediate applications. The market for frequency correction units in commercial power grids that can handle about 2 MW is a several billion dollars today in the US. With only a few large players, such as ABB, Parker, Eaton and General Electric, it leaves room for smaller players such as Princeton Power Systems. The proposed research can significantly reduce the size, weight, and most importantly, the cost for these systems. It will also help to improve the power distribution infrastructure in the US, save energy and reduce the cost of electricity to consumers. Even a small percentage of marketshare will directly translate into a significant sales volume and growth opportunity for our company. The proposed development will also create new, well paying jobs and opportunities in the economically depressed area where the company is located and where most jobs today are low paying service jobs.
Keywords: tip speed, tip speed, metglas, high speed motor, Magnetic Bearings, Cobalt steel, dynamic generator, Carbon Composites, SMCs (soft magnetic composites)
