COST REDUCTION DESIGNS OF A LARGE RANGE OF HIGH PERFORMANCE PM ALTERNATORS AND CONTROLS WITH A PARALLEL EMPHASIS ON ...

FOUR BEARINGLESS, SHAFT MOUNTED GENERATORS WITH OUTPUTS OF 10, 100, 500 AND 1000 WATTS OF 12-15 V DC WILL BE DESIGNED AND COMPUTER MODELED TO BE DRIVEN BY MODEL AIRPLANE SIZE RECIPROCATING ENGINES. DESIGN COMBINATIONS OF IRONLESS DISK AND IRON LAMINATION CYLINDRICAL GENERATORS USING RARE EARTH AND CERAMIC PERMANENT MAGNETS WILL BE MODELED FOR RELIABILITY WITH THE LOWEST WEIGHT AT THE HIGHEST EFFICIENCY RELATED TO ESTIMATED MATERIAL COST OF PRODUCTION MODELS. PROPRIETARY HIGH PERFORMANCE GENERATOR DESIGN SOFTWARE PREVIOUSLY WRITTEN BY THE PI (PRINCIPLE INVESTIGATOR) WILL BE MODIFIED TO OPTIMIZE THE DESIGN AND OPERATION OF THESE GENERATORS. A NUMBER OF HIGH PERFORMANCE GENERATORS, INCLUDING A 500 WATT GENERATOR DRIVEN BY A 2CC ENGINE HAVE BEEN DESIGNED, BUILT AND TESTED FOR INDUSTRIAL APPLICATIONS WITH THE ASSISTANCE OF THIS SOFTWARE. AS GENERATOR WEIGHT IS REDUCED, EFFICIENCY DROPS AND MORE FUEL IS REQUIRED PER FLIGHT MISSION. AN OPERATING MODEL WILL BE WRITTEN TO OPTIMIZE TOTAL MISSION WEIGHT AND MAINTAINABILITY. A 10 WATT PROTOTYPE (OR AS SPECIFIED) WILL BE BUILT AND TESTED TO COMPARE PERFORMANCE WITH THE COMPUTER DESIGNED MODEL FOR RPM VS OUTPUT, EFFICIENCY AND WEIGHT. ANTICIPATED BENEFITS/POTENTIAL COMMERCIAL APPLICATIONS - THE LIGHTWEIGHT GENERATOR WILL PROVIDE ON-BOARD ELECTRICAL POWER TO ENABLE LONG DURATION FLIGHTS OF VERY SMALL AIRCRAFT. USES INCLUDE SERVEILANCE, AERIAL MAPPING, EXPENDABLE FLIGHTS INTO HAZARDOUS SITUATIONS AND LOW COST RELAY PLATFORMS. THE MINIATURE ENGINE DRIVEN GENERATOR PROVIDES THE BASIS FOR VERY SMALL PORTABLE GENERATOR SETS. A QUART SIZE GEN SET WOULD PRODUCE 500 WATTS FOR EMERGENCY LIGHTING OR REMOTE CAR OR TRUCK STARTING IN THE WINTER.