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Electromagnetic Design of Aircraft Synchronous Generator with High Power-Density

This paper discusses the methodology for the electromagnetic design of an aircraft synchronous generator with high power-density. A new method is proposed to more accurately model the air-gap of a salient pole rotor through expanding the inverse of an effective air-gap function. The corresponding magnetic fields from the rotor and stator windings, as well as the expressions of back EMF, are derived using the air-gap model. The stator inner diameter and length are designed by considering a proper cooling scheme and maximum peripheral-speed of the rotor. This allows for design of the stator winding and slot geometry, including the derivation of a formula for the stator core thickness. The air-gap and salient pole shoe face can be designed using the desired specifications for power factor and torque angle. The rotor windings and geometry are subsequently designed. Following the above procedure, a 200 KVA high power-density synchronous generator with 12 krpm rotational velocity is obtained. Finally, the design is verified and finely tuned using ANSYS RMxprt, Maxwell FEM software, and SimuLink.