Selecting Optimal Dimensions for a High-Temperature Aircraft Starter Generator

Abstract

The notion of a more electric airplane figures strongly in the design of new aircraft. The task that has to be done is to integrate an electric machine directly with a high- and/or low-pressure aircraft-engine shaft. As a result, it is possible to reduce the engine’s weight–size parameters, attain better reliability and fuel saving, and cut down aircraft maintenance costs. To realize this, it is necessary to design a highly efficient high-temperature starter generator able to work in harmful environmental temperatures with minimal technological possibilities for cooling. This article presents a design of the starter generator with an external rotor for integration with a high-pressure aircraft-engine shaft. To attain better parameters and characteristics of the proposed design, optimization by multiple criteria in the Ansys Maxwell software package is conducted. The optimal dimensions of the SG with an external rotor are determined by genetic algorithms. The optimized starter generator has minimal weight–size parameters and high energy performance and works with minimal losses. The operability of the starter generator is assessed by computer modeling on the basis of which a test mockup is designed. The tests are conducted in no-load and loaded modes. The test results show the appropriateness of the selected design, the operability of the starter generator, and its efficiency for integration with the HP shaft.