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Permanent Magnet HighSpeed Generator for FTT Micro Turbine

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Sleeve made of pre-stressed high-strength material. Low. High. Medium. Mass / Inertia ... Mechanical strength. Composite resin. Stainless steel. Aluminum ... – PowerPoint PPT presentation

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Title: Permanent Magnet HighSpeed Generator for FTT Micro Turbine


1
Permanent Magnet High-Speed Generator for FTT
Micro Turbine
  • Jinho Kim, Daniel Kirk and Hector Gutierrez
  • Mechanical Aerospace Engineering
  • Florida Institute of Technology

2
Performance Requirements
3
Proposed Design
  • Machine type Permanent magnet synchronous
    generator
  • Number of Poles 4
  • Number of Phases 3
  • Nominal Speed 100,000 RPM

4
Proposed Electrical Layout
Magnet
Inner core
Shaft
Outer core
Physical Layout
Winding Pattern
5
Electromagnetic Performance
Simulation by finite element analysis using
MAXWELL-Ansoft Four-pole, three-phase design _at_
100,000 RPM
6
Electromagnetic Performance
Output Phase Voltage for NdFeB35, max 415 V
(for SmCo28, max 402 V)
Air gap flux density for NdFeB35, max 0.6 T
(for SmCo28, max 0.52 T)
7
Mechanical Layout in High-Speed Electrical
Machinery (18 to 120 kRPM)
U.S. Patent 5,144,735 (Stark et al.) U.S.
Patent 5,687,471 (Noguchi et al.)
8
Mechanical Layout in High-Speed Electrical
Machinery (18 to 120 kRPM)
U.S. Patent 4,625,135 (Kasabian et al.)
9
Proposed Mechanical Design
  • Permanent magnets bonded to grooves in rotor core
  • Torsional stress in rotor shaft is modest ( 2.3
    MPa)
  • Critical mechanical requirement given by
    centrifugal forces
  • Containment sleeve required to protect rotor from
    large centrifugal forces
  • Sleeve made of pre-stressed high-strength material

10
Proposed Mechanical Layout
turbine shaft permanent magnets (4) containment
sleeve
rotor core stator
11
Analysis of Critical Mechanical Stress
Structural FE analysis of sleeve using ANSYS
  • Rotational Speed 100k RPM
  • Sleeve Material
  • AISI Type 302 Stainless Steel
  • Tensile Strength, Ultimate 495 MPa
  • Tensile Strength, Yield 160 MPa
  • Sleeve thickness 1mm
  • Magnets assumed not bonded or bolted - supported
    only by sleeve
  • Max stress at sleeve 157 MPa
  • Actual stress would be much less since magnets
    are bonded and/or bolted

12
Thermal Analysis
FE conduction convection analysis using ANSYS
450 K
  • Heat source given by stator coils
  • 2-D axisymmetric model
  • 3 cases of air speed
  • Sleeve thickness 1mm
  • Thermal Conductivity
  • Stainless steel 16.2 W/m-K
  • Permanent magnet 9 W/m-K
  • Copper 385 W/m-K
  • Carbon steel 49.8 W/m-K

Q Ri2
z
r
Air 300K 50 m/s300 m/s
13
Results Temperature Distributions
Thermal Analysis
Air flow 50 m/s
Air flow 300 m/s
Air flow 100 m/s
Layers shaft (stainless), inner core (carbon
steel), magnet, sleeve (stainless), air gap,
copper, outer core (carbon steel).
14
Conclusions
  • Proposed design meets all electrical requirements
  • Containment of centrifugal forces achieved by
    pre-
  • stressed sleeve
  • Critical mechanical stresses verified under
    worst-case
  • conditions
  • Estimated operating temperature 410K
  • Proposed magnetic material (SmCo5) has max
    service
  • temperature of 523K
  • Loss of nominal magnetic coercivity at the
    operating
  • temperature 2

15
Future Work
  • Detailed mechanical component design
  • Detailed 3-D finite-element verification of
  • Electromagnetic performance
  • Structural integrity
  • Thermal analysis Heat transfer
  • Analysis / design of electronic power converter
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