SBIR-STTR Award

An innovative solution for improvement in power density, efficiency, and reliability of the electric starter generator (ES/ G) is proposed using induction technology. Single set stator-rotor assembly per power section and lack of rotating windings and rectifiers will substantially improve power density and reliability. The induction generator is turned off within a fraction of a second under fault conditions.It provides regulated voltage output. Ways for improving efficiency and thermal management are proposed including sealed cooling system instead of spray cooling, high thermal conductivity filled epoxy insulation, improved processing of electrical steel for the stator and rotor cores. The result is a compact generator design that will exceed the power density and efficiency targeted for this application. Phase I activity includes conceptual electromagnetic and thermal design and detailed analysis to verify performance, followed by Option period for further electromagnetic analysis using Finite Element techniques, and a detailed insulation scheme investigation, as well as complete layout of the of the dual output starter generator. The results of Phase I and Option will ensure development of demonstrable compact and efficient electric starter generator hardware in Phase II.

Benefit:
Enhanced efficiency and power density, as well as improved reliability for high speed starter generator will be the main benefits of this effort. The applications are mainly in turbine driven or gear-box driven generators for aircraft use having DC voltage at the terminals. In commercial and industrial applications the same generator with the addition of dc to ac converter will find uses in distributed power systems and in emergency power generator sets.

Keywords:
high speed induction generator, high speed induction generator, induction generator, starter generator, aircraft generator, high speed induction motor

Fighter jets use dual starter generators that provide dc power in two channels, and also provide the mechanical power during start mode for starting the propulsion engine. A current application of the dual starter generator has two generator channels each capable of providing 80 kW power at 270 Vdc. This proposal offers application of a different generator technology to support the growing power needs, by producing 25% more power with reduced overall weight of the generator. Additionally due to better cooling techniques, the generator losses are reduced and the generator efficiency in improved. Due to the lower component count of the generator, the reliability of the generator is expected to be better and the production costa are anticipated to be lower. This proposal includes a plan to complete the design of the dual starter generator, and the associated controller, and test the system in a laboratory environment. The test results will be compared to the requirements of fighter aircraft. This will be followed by a laboratory demonstration.

Benefit:
Reduced Weight, improved reliability, increased power by 25%, and anticipated lower production cost of the dual starter generator for jet fighters.

Keywords:
high speed power generator, induction technology, generator electric power, light weight system