High Power Density Electric Generator for Army Rotorcraft

The US Army helicopter fleet consists of upgraded helicopters that were originally designed in the 70's and 80's. The more electric aircraft philosophy has put a strain on electrical systems, and has exhausted their growth potential. Replacing the generator on an existing engine/gearbox poses a challenge because of weight, overhung moment, and space limits. Therefore, most likely the only solution to these issues is to provide a generator with more power that meets the original requirements. In simpler terms a generator with higher Power Density is desirable. Improved stress, thermal and rotor dynamic software packages allow the designer to optimize the mechanical design and minimize weight with no sacrifice in component integrity. Furthermore, improvements in production equipment make thin walled housings affordable which are significantly lighter than castings with thicker walls due the inherent porosity of the cast material. IPS team members all of whom where AlliedSignal employees were involved in the design and production of both the Longbow Apache and Blackhawk helicopter generators. IPS is currently overhauling the Apache and Blackhawk generators IPS has increased the power of an oil-cooled generator by 57% and designed an air-cooled generator for the P3 aircraft with a 66% increase in power density.