DESIGN AND ANALYSIS OF DC POWER SUPPLY (28 V) FOR AEROSPACE APPLICATION

V. Jayashree Shivkumar, R. Periasundaram#, M.Vadivel# Scientist E, #T O B, Aircraft Projects Division, LCA, CVRDE, Avadi, Chennai 600054. # Project Associate, Electrical Department, IIT Madras, Chennai- 600036

Abstract: The present day trend in efficient power

generation is to use Permanent Magnet Generator for Aircraft Applications. The technology used in the military / aircraft applications for power generation comprises three-stages / two stages generator configuration. The advantages of Permanent Magnet Generator over conventional generators are discussed in this paper. Since the rotor excitation winding has been replaced by Permanent Magnets, the efficiency of the generator has improved as the copper losses in the rotor has been eliminated. A 1 kW Permanent Magnet Generator using rare earth permanent magnet has been designed, developed, extensively analyzed for its performance parameters. This promising technology can overcome the problems in a constant speed machine in terms of power requirement, reliability, ease of maintenance and higher operating speed and temperatures.

In-view of the lower weight and size and due to low EMI/EMC interference, it is decided to select permanent magnet brushless generators for the design of Aerospace Applications.

A comparison table on the different types Generators is shown in Table 1. Table 1. Comparison of Different Types of Generators Surface Interior Mounted Permanent Induction Permanent Magnet Generator Magnet (IPM) (SPM) Generator Generator 1.0 0.7 0.7 1.0 1.05 1.05 1.0 1.0 1.2 1.0 1.0 0.2 0.3 0.8 0.6

Keywords: Brushless Permanent Magnet Generator, and VSCV concept. I. INTRODUCTION The Electrical generators can be classified as brush type and brushless type. The advantages and disadvantages of both the types of generation is detailed below. Advantages of brushed scheme Simple and conventional Cost effective Disadvantages Maintenance Ageing Reliability Power loss Advantages of Brushless generator Good power density Reduced size No EMI/EMC interferences Disadvantages: No Excitation control De-magnetizing effects

Cubic Volume Efficiency Power factor Constant Power range Max. Rotor surface speed

* The values are based on relative index with respect to Induction generator. Permanent magnet synchronous machines have found wide applications in various fields. Compared to other electrical machines, PM machines combine the advantages of induction machines and common synchronous machines in high efficiency, power factor and power density, low size and weight. Various types of permanent magnets like Alnico, ferrites, Samarium cobalt and NdFeB are available. After exploring the B-H characteristics of all these permanent magnets it is decided to choose NdFeB PM magnets for the design of generator. The choice of permanent magnets calls for high residual flux density with high MMF to demagnetize the magnets.

Typical range of NdFeB grades is shown in Fig.1,

conventional fundamental equations for the given output ratings. The variable voltage derived as a function of speed is rectified and converted to a constant 28VDC voltage (VSCV) for variable load and speed conditions using MOSFET power switches with PWM concepts.

The generator design parameters are listed below Table 2. Input data of 1 kW Generator Parameters Power Factor, pf Speed, N (rpm) Stacking Factor, stf Slot Filling Factor, Ks Short Pitching (Slot) Magnet No of Poles, P No of Slots/pole/phase, q Stator Outer Dia, ods (mm) Rotor Outer Dia, odr (mm) Machine Length, Lc (mm) Magnet Length, lm (mm) Slot Depth, Sh (mm) Tooth Width, Wts (mm) Core Depth, dcs (mm) No. of Turns per Coil No. of Coils per Phase Current Density, J (A/Sq.mm) Value 0.8 775 0.96 0.5 1 MQ3G32SH 12 1 145 83.5 114 8 18.5 4 13.5 7 12 5

Fig.1. Typical Range of NdFeB Grades For our application other essential factors like very high overload-factor and the maximal permitted short-circuit current without permanent demagnetization of the magnets, had to be considered. II. PROTOTYPE DESIGN A 1 kW PERMANENT MAGNET SYNCHRONOUS MACHINE is designed and developed using NdFeB as permanent magnets. The SURFACE MOUNTED PERMANENT MAGNET on rotor is designed and built to prove the new technology concepts in the optimized configurations. A shielding cylinder surrounding the magnets on rotor protects the magnets against centrifugal forces. The ratings of the 1 kW generator are as follows Power output : 1 kW Input Speed : 200 RPM to 900 RPM The generator laminations are cobalt iron Vanadium featuring very good magnetic and mechanical strength. It is a 12-pole machine with 36 slots .The machine is designed to generate 28V.dc. It caters maximum torque near the rated speed. The geometry and the number of poles are fixed. The design of the generator is obtained from the

III. SIMULATION ANALYSIS A powerful Electro-Magnetic Simulation package was used for design analysis and performance validation at no load and full load at transient conditions. To make the model suitable to optimize the machine design, all the parameters are calculated from the dimensions and material properties of the machine. The simulation data ensures that there is less armature reaction in the machine. For an optimum design, Ampere-turns spent by magnet should be approximately equal to the Ampere-turns spent by stator core teeth and airgap. Using the simulation packages the flux density at various critical parts of the generator is derived. The no load flux density of the magnet is shown in Fig. 2.

IV. PROTOTYPE PERFORMANCE VALIDATION Various load tests have been carried out on the generator, which is shown in fig3. The Test Data is matching with simulation data analysis and it is tabulated in table 4. Various Performance tests like open circuit, load tests and efficiency analysis have been conducted and the test validation is matching with the simulation data and the performance graphs are shown in Figs.4, 5, 6, 7 & 8.

Table 4. Test data matching with simulation data Quantities Fig. 2. No Load Flux Density in Magnet The simulation test results are given in table 3. The results confirm that the performance requirements of the Generator will be met. Table 3. Output data of 1Kw generator Quantities Voltage, V (Volts) Current, I (Amps) Output Power, Pout (Watts) Efficiency, Eff Simulation program 72.155 (VL) 15 (IL) 1248.3 0.9117 Voltage, V (Volts) Current, I (Amps) Output Power, (Watts) Efficiency, Eff 82.9 (VL) 13.6933 (IPh) 1121 80% to 90% Test data Simulation program 72.155 15 (IL) 1248.3 0.9117

Fig. 3. Single stage PM Generator

Fig. 4. Open Circuit Characteristics

100 90 80 70
Efficiency (in %)

60 50 40 30 20 10 0 0 200 400 600

Output Power (in Watts)

Speed ~ 800 RPM

800

1000

1200

Fig. 5. Load Graph at 800 RPM

Fig. 8. PM Generator efficiency V. THERMAL ENVELOPE

(a) The temperature study was carried out to determine the temperature rise on various parts of the generator and to evaluate the magnet characteristics with increased temperatures. The resistances (cold) of the winding at ambient temperature are: Rr = 0.387 ohms Rb = 0.384 ohms Ry = 0.381 ohms Ambient Temperature, T1 = 30 oC
Fig. 6. Speed Vs Power

After noting the initial values, the machine is loaded fully and is run for nearly Two hours. As the machine reaches a steady temperature of 60oC and it is switched off. The readings are shown below. Table 5. Heat run Test data
Time Resistance Time (1 Hour +) (Minutes) 10 20 30 40 50 60 Resistance Time (2 Hour +) (Minutes) 10 20 30 40 50 60 Resistance

Fig. 7. Volt Ampere Characteristics at Different Speeds

(Minutes) 10 20 30 40 50 60

(Ohms) 0.421 0.422 0.417 0.413 0.412 0.411

(Ohms) 0.411 0.410 0.410 0.409 0.407 0.406

(Ohms) 0.406 0.405 0.404 0.403 0.403 0.401

The resistance of the hot wire is raised upto a value of 0.422ohms and after 2 hours it started to decay exponentially. (b) There could be about 60 % increase in the value of current density by increasing the Power output to nearly 1.6 kW from the design value of 1.0 kW. As the temperature rise is well with in limits of the insulation there is no requirement to increase the insulation level.
INFERENCES [A] A feasibility study has been carried in the field, variable speed constant voltage operation in single stage configuration. [B] The generator shall be loaded upto 1.5 kW. For 5 minutes. [C] The design of insulation system is compact. [D] Max. temperature rise is 27C.

REFERENCES [1] [2] [3] [4] [5] Electrical Machine Design A. K. Sawhney. Brushless Permanent Magnet and Reluctance Motors Drives T. J. E. Miller. Performance and Design of AC Machines M. G. Say. Electric Motor Drives R. Krishnan, Virginia Tech, Prentice Hall of India, 2002. Design and Analysis of 42V Permanent Magnet Generator for Automotive Applications, Ali Keyhani, IEEE Trans on Energy Conversion, March 2003.

FUTURE SCOPE OF WORK Based on the simulation and test results, the research work can be further extended to 5 kW power requirements at high-speed operation in single stage. This in turn results in a more compact configuration for airborne requirement.

ACKNOWLEDGEMENTS We wish to express our gratitude to Dr. D. Hanumanna, Outstanding Scientist and Director CVRDE, Avadi, Shri. S. Sundaresh, Sct. G, Additional Director (Technology), Prof. G. Sridhara Rao, EEE, IITM, Shri. C. Chandrasekaran, PD-AP and Prof. P. Sasidhara Rao, EEE, IITM for the constant guidance and immense support for doing this project in CVRDE.