High Power Variable Frequency Generator for Large Civil Aircraft
By M. Olaiya and NBuchan
TRW Aeronautical Systems, Lucas Aerospace, Maylands Avenue, Hemel Hempstead, Hertfordshire HP2 4SP
ABSTRACT
2X W Aeronautical Systems (zucas
Aerospace) set out to develop a high
power, wide speed range variable
fiequency (VF) generator suitable for
large civil aircrap. A high-speed
generator is desirable because it will be
smaller and lighterfor a given output and
because its higher output@equency will be
more compatible with economically sized
consumer equipment. The three-year
program, which was part funded by the
D?7 under its CARAD 11 initiative is
described.
INTRODUCTION
TRW Aeronautical Systems (Lucas
Aerospace) has pioneered the application
of variable fiequency electrical power
generation in a turbofan-engined aircraft,
winning the contract for the Global
Express Electrical Power Generation and
Distribution System.
Variable frequency technology has many
benefits, particularly in terms of cost,
weight and reliability. The company
recognised that it must make the move
fi-om small business jet aircraft to medium
and large civil aircraft. To achieve this a
number of technical challenges had to be
overcome. These were:
Optimised electromagnetic design for
wide fiequency range operation
0 High integrity, high speed rotor
0 Consistent thermal management over
speed range
The three year project which started in
April 96 was part funded by the DTI under
its CARAD II initiative. It was undertaken
in partnership with four other companies:
0 The Barden Corporation (UK) LTD -
operating fiom Plymouth, Devon a
mandacturer of super-precision rolling
contact bearings.
Aeromet International PLC - suppliers
of fully machined precision aluminium
and magnesium castings to the
aerospace, defence and motor-sport
industries.
Telcon Ltd - principally engaged in the
manufacture of soft magnetic alloys
and applied magnetic electronic
devices.
The Component Design and Integrity
(CDI)Group within the Department of
Mechanical Engineering at University
of Nottingham - undertakes research
and consultancy work related to the
design and integrity of engineering
components.
PROJECT DESCRIPTION
OBJECTIVES
To develop the necessary technologies
required to realise a 120kVA, 2.05:l speed
range, variable fiequency generator, the
following factors were considered:
0 Optimised electromagnetic design for
efficient operation over a wide
fiequency range
0 Magnetic material optimised for high
strength and low losses
0 High integrity, high speed, four-pole
rotor
0 High strength lightweight fiame
0 Methods for consistent cooling of
wide-speed range generator
0 IOptimised high speed bearing design
CHALLENGES
The principal challenges involve the
electrical performance, the mechanical
integrity and the thermal management,
these are influenced by the operating
speed, size and weight of the generator.
Electrical Performance
The generator speed range is 11,400 to
23,400 rpm resulting in a frequency range
of 380 to 780Hz. The electrical
performance must be optimised to provide
a high quality of supply over this
frequency range whilst maintaining
minimum weight and maximum
efficiency.
Mechanical Integrity
To design a rotor capable of operating to
an over-speed of 27,000rpm that is stiff
enough to limit shaft growth and bending.
The rotor must also accommodate the
loads and stress cycling due to the variable
speed of operation.
Thermal Management
With a generator operating over a wide
speed range the consistent provision of
adequate cooling oil is a significant
challenge. The rotor construction dictates
that the main rotor is flood cooled with
spray cooling elsewhere. The size of the
rotor determines the oil jet velocities and
flows and these must be optimised to
achieve maximum cooling and efficiency
over the full speed range.
DESIGN OVERVIEW
The generator is a 3-stage brushless oil
cooled machine providing a nominal 115v,
12OkVA, 3 phase and 380-78OHz output.
IX DEBEARING
w
Oil outlet NDE
Oil outlet DE
The three stages of the machine are the
permanent magnet generator (PMG), the
main exciter (ME) and the main alternator
(MA). These are connected in cascade
with the PMG powering the ME via the
generator control unit. The ME supplies
the MA via shaft mounted diodes.
The three static electromagnetic
components are supported in two precision
sand-cast aluminium alloy housings. The
three rotating electromagnetic components
are mounted on a common shaft,
supported by a pair of ceramic ball
bearings at either end.
Cooling oil is supplied directly into the
rotor shaft and distributed via a series of
jets to cool windings and lubricate
bearings. The main rotor is flood cooled
for maximum efficiency.
The MA rotor is assembled inside a large
diameter Jnconel shaft to ensure the
stiffhess and integrity of the rotor. This
also provides the means to flood cool the
MA rotor.
12OkVA VF Generator
TEST SUMMARY
Development testing can be divided into
three categories. Dynamic Performance,
Thermal & Oil Management and Electrical
Performance.
DYNAMIC TESTING
Growth & Whirl
An initial test on each rotor to establish the
growth of the rotor under the action of
centrifugal forces (CF). Measuring the
whirl indicates the critical speed of the
rotor.
Over-speed
Each rotor is subjected to a five minute
over-speed. This test stabilises the rotor
windings after growth & whirl. The rotor is
dynamically balanced prior to oil
management testing.
THERMAL & OIL MANAGEMENT
The rotor oil management tests are carried
out in a custom-made spin pot. The spin
pot allows the flow of oil fiom each jet on
the rotor to be measured and therefore
optimised to achieve maximum cooling.
Mechanical losses in the form of drag and
churning can also be measured
A number of generators were fully
thermocoupled and can be thermally
mapped to ensure optimum cooling. The
inlet and outlet oil temperatures are
recorded and used to monitor overall
efficiency at any given electrical load.
ELECTRICAL TESTING
The electrical and electromagnetic
perfomance of the generator is confirmed
with the following tests:
0 Pilot Exciter Characteristics
0 Open Circuit Characteristics
0 Short Circuit Capability
0 Load Excitation and Heating
0 Balanced & Unbalanced Loads
0 Waveform Analysis
0 Loadswitching
Efficiency
Each of these tests is conducted at the
extremes of oil temperature, over the speed
range and at various load conditions.
313
TEST RESULTS
The dynamic tests show that the material
choice and rotor construction is critical in
achieving the high speeds envisaged for
the high power.
The high rotor speeds generate high oil
velocities and significant shearing losses in
the oil leading to poor efficiencies. Careful
attention to the passage of oil into and out
of the generator is vital to reduce these
losses to a minimum, particularly as
mechanical heat loss rises with speed.
Further modifications are under evaluation.
Testing to date shows that the generator
meets the target electrical specification.
Notably the unit will deliver 12OkVA at
unity to 0.75 power factor over the
frequency 380 - 720Hz.
The power quality is a function of the load
excitation, unbalanced load, waveform
analysis and load switching tests. Initial
indications are that the power quality
meets specification
MAGNETIC MATERIAL
The challenge for Telcon Ltd, Within the
project, was to develop a soft magnetic
alloy with increased strength without
sacrificing magnetic performance when
compared With existing high saturation
alloys.
A yield strength target value for the rotor
laminations was set at 600MPa This has
been achieved with the new cobalt-iron
alloy together with meeting the target
magnetic performance levels for the rotor
and stator laminations covering both losses
and induction at specified field levels.
The University of Nottingham have carried
out a study of the fatigue and fiacture
properties for the magnetic iron material at
15OoC, the temperature at which the
material will operate. The outcome of this
work has confirmed that the material has a
peak fatigue limit of lo6 cycles at peak
stress levels less than 800MPA with a ratio
of maximum to minimum stress of 0.1.
COPPER CONDUCTOR MATERIAL
The University of Nottingham have also
undertaken a study of the creep and fatigue
properties of annealed high conductivity
copper at temperatures up to 250°C.
Copper is chosen for its superior
conductivity and is used in all of the
wound components in the generator.
There is little data available on the
behaviour of the copper at elevated
temperatures. The data generated from this
study will be used to optimise future
designs. In particular it will be used to
improve the design of conductor
connections subjected to high centrifugal
forces.
The tests have shown that fatigue lives at
200°C are more than two times longer than
the lives at 25OoC.
Systems intends to investigate in the near
future, are:
Increase the generator output power.
Improvements to the oil management
arrangement to further improve the
efficiency.
As civil aircraft become larger it is clear
that the demand for electrical power will
increase. In the same way the More
Electric Aircraft (MEA) will require more
power to supply the ever-increasing
number of electrical systems. The work
covered by this project is a significant step
towards the needs of the MEA.
Acknowledgements
The authors would like to acknowledge the
contribution to this paper fiom Telcon Ltd
and The University of Nottingham.

CONCLUSION
TRW Aeronautical Systems (Lucas
Aerospace) has successfully designed and
manufactured a 120kVA VF generator and
is currently in the process of developing
this machine. The generator has
demonstrated the ability to deliver variable
frequency power over a frequency range of
380 to 720Hz. Initial indications are that
the power quality also meets specification.

The speed and size of the generator have a

major impact upon the integrity of the rotor
and the efficiency that can be achieved.
These are both mechanical issues and can
easily be overcome. The company is in the
process of testing refinements that will
address these issues.

The test programme has highlighted the

areas of the design that must be addressed
to achieve variable frequency generators
rated at 120kVA and beyond.
Developments, which TRW Aeronautical

0 1999 The Institution of Electricai Engineers.

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