In-Line High Power Density PM Generator

SatCon proposes to develop two in-line high power density permanetn generators for light tactical vehicle applications. The combination of a large diameter rotor, high energy-product rare earth magnets, and a large magnet length permits brushless power generation capability well in excess of that specified with good voltage regulation and efficiency. SatCon has developed and analyzed two preliminary designs for permanent magnet generators, both of which are roughly 5.5 inches long by 15.5 inches in diameter and weight 75kg. Initial analyses indicate that the first, a 3 pole-pair design, can generate 10 kW at 1200 rpm, while maintaining a voltage regulation of better than 4% and an efficiency of better than 99%. This same machine, with forced air cooling, however, can deliver 26 kW, while maintaining a voltage regulation of 10% and winding losses of 570 W. The second design, a 2 pole-pair design, will deliver 20 kW at 1800 rpm with a voltage regulation of better than 5% and an efficiency of better than 99%. With forced air cooling, it can deliver 39 kW, while maintaining a voltage regulation of 10% and winding losses of 570 W. Liquid cooling would allow greater generating power capacity. If required, greater magnet length will improve voltage regulation. The Phase I will proceed through requirements definition, design tradeoffs, and detail design to arrive at a optimum design which would be built and tested in a Phase II. Emphasis will be given to thermal management, efficiency, voltage regulation, and mechanical ruggedness and mounting.