Design of an aircraft generator with radial force control [version 3; peer review: 2 approved]
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...
| Main Authors: | , , , , , , , , , |
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| Format: | Article |
| Language: | English |
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F1000 Research Ltd
2023-04-01
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| Series: | Open Research Europe |
| Subjects: | |
| Online Access: | https://open-research-europe.ec.europa.eu/articles/2-73/v3 |
| _version_ | 1797838024603598848 |
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| author | Marcus Gärtner Stephan Neus Christian Brecher Maik Hoppert Hans-Martin Eckel Chris Gerada Barry James Mauro Di Nardo Michele Degano Mohammad Reza Ilkhani |
| author_facet | Marcus Gärtner Stephan Neus Christian Brecher Maik Hoppert Hans-Martin Eckel Chris Gerada Barry James Mauro Di Nardo Michele Degano Mohammad Reza Ilkhani |
| author_sort | Marcus Gärtner |
| collection | DOAJ |
| description | 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. |
| first_indexed | 2024-04-09T15:34:08Z |
| format | Article |
| id | doaj.art-2b23b25cb6c64806b2f153517c3d8c34 |
| institution | Directory Open Access Journal |
| issn | 2732-5121 |
| language | English |
| last_indexed | 2024-04-09T15:34:08Z |
| publishDate | 2023-04-01 |
| publisher | F1000 Research Ltd |
| record_format | Article |
| series | Open Research Europe |
| spelling | doaj.art-2b23b25cb6c64806b2f153517c3d8c342023-04-28T00:00:00ZengF1000 Research LtdOpen Research Europe2732-51212023-04-01217119Design of an aircraft generator with radial force control [version 3; peer review: 2 approved]Marcus Gärtner0https://orcid.org/0000-0003-3615-8152Stephan Neus1Christian Brecher2Maik Hoppert3Hans-Martin Eckel4Chris Gerada5Barry James6Mauro Di Nardo7https://orcid.org/0000-0003-0137-4920Michele Degano8Mohammad Reza Ilkhani9https://orcid.org/0000-0002-3044-9592Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, GermanyLaboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, GermanyLaboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, GermanyRomax Technology Ltd., a Hexagon company, Ergo House, Mere Way, Ruddington Fields Business Park, Nottingham, NG11 6JS, UKLaboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, GermanyPower Electronics, Machines and Control (PEMC) Research Centre, University of Nottingham, Engineering Department, Jubilee Campus, Wollaton Road, Nottingham, NG8 1BB, UKMSC Software GmbH, a Hexagon company, Am Moosfeld 13, Munich, 81829, GermanyPower Electronics, Machines and Control (PEMC) Research Centre, University of Nottingham, Engineering Department, Jubilee Campus, Wollaton Road, Nottingham, NG8 1BB, UKPower Electronics, Machines and Control (PEMC) Research Centre, University of Nottingham, Engineering Department, Jubilee Campus, Wollaton Road, Nottingham, NG8 1BB, UKPower Electronics, Machines and Control (PEMC) Research Centre, University of Nottingham, Engineering Department, Jubilee Campus, Wollaton Road, Nottingham, NG8 1BB, UKWith 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.https://open-research-europe.ec.europa.eu/articles/2-73/v3Aircraft generator radial force control bearing friction bearing loads efficiency validationeng |
| spellingShingle | Marcus Gärtner Stephan Neus Christian Brecher Maik Hoppert Hans-Martin Eckel Chris Gerada Barry James Mauro Di Nardo Michele Degano Mohammad Reza Ilkhani Design of an aircraft generator with radial force control [version 3; peer review: 2 approved] Open Research Europe Aircraft generator radial force control bearing friction bearing loads efficiency validation eng |
| title | Design of an aircraft generator with radial force control [version 3; peer review: 2 approved] |
| title_full | Design of an aircraft generator with radial force control [version 3; peer review: 2 approved] |
| title_fullStr | Design of an aircraft generator with radial force control [version 3; peer review: 2 approved] |
| title_full_unstemmed | Design of an aircraft generator with radial force control [version 3; peer review: 2 approved] |
| title_short | Design of an aircraft generator with radial force control [version 3; peer review: 2 approved] |
| title_sort | design of an aircraft generator with radial force control version 3 peer review 2 approved |
| topic | Aircraft generator radial force control bearing friction bearing loads efficiency validation eng |
| url | https://open-research-europe.ec.europa.eu/articles/2-73/v3 |
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