High Density, High Efficiency Electrical Power Generation

Electrical starter/generators (ESGs) have become increasingly complex in design and integration due to significant power demand increases in more electric aircraft initiatives such as the Joint Strike Fighter (JSF). These new ESG systems must provide high performance and high efficiency with limited active cooling availability. In order to satisfy the power demands and harsher environments anticipated in JSF block upgrades or future military and civilian aircraft platforms, new technologies must be investigated that allow significant performance improvements with increased power density and higher operating temperatures. To address these requirements, PC Krause and Associates (PCKA) is developing a new generator technology that removes temperature limitations associated with traditional synchronous generator designs. This new technology, called the ac-field electrical synchronous generator (ACESG), can operate at temperatures of 500 degrees Celsius and beyond without sacrificing output power capability. Being able to operating at such temperatures has significant advantages: 1) active cooling oil with much higher inlet temperatures can be utilized, 2) heat can be radiated and convected into the environment, and 3) direct integration of the ACESG at the turbine engine becomes possible. All these advantages will result in significant reduction of active cooling, thus reducing size and increasing power density of the ESG system. In the Phase I effort, PCKA will utilize high-fidelity electrical, thermal, and mechanical modeling and simulation to design and optimize the ACESG to JSF ESG specifications. Appropriate high-temperature material characteristics will be considered in the design process to ensure a viable design. At the end of the Phase I effort, the goal is to demonstrate the feasibility and capabilities of the ACESG with a detailed assessment of thermal and electrical performance compared to the existing JSG ESG. If the Phase I effort is successful, PCKA will demonstrate a hardware prototype in the Phase II. If successful, PCKA will transition the ACESG technology to DoD programs under Phase III contracts and/or commercial applications.