Advanced high-power generator for airborne applications

This report summarizes the work accomplished through Phase II of a four-phase program to design and build the stator and housing for a 5-Mw generator and test the complete 5-Mw generator. The PM rotor for this stator and housing is being built under a separate AF companion contract. This work is part of an Air Force exploratory program for high-power airborne electrical power supply technology. Phases I and II encompassed a 10-month period from April 1981 to January 1982. In Phase I, a lightweight, high-power density stator/housing was designed and optimized with computer model BIGMAG for integration with a permanent magnet rotor into a 5-Mw alternator with a specific weight of 0.1 lb/kw or less. Components with potential for significant weight reduction were identified for testing in Phase II. Among these critical components are a novel liquid-cooling scheme for the stator and an elastomer bore seal. Fabrication drawings were prepared for all individual parts of the stator and housing along with a detailed fabrication plan. A plan for testing the complete 5-Mw generator under full-load conditions at the AF Compressor Research Facility also was prepared. Fabrication and testing will be done in Phases III and IV, respectively.