High Density, High Efficiency Electrical Power Generation Navy SBIR FY2010.3 Sol No.: Navy SBIR FY2010.3 Topic No.: N103-207 Topic Title: High Density, High Efficiency Electrical Power Generation Proposal No.: N103-207-0336 Firm: PC Krause and Associates, Inc. 3000 Kent Avenue, Suite C1-100 West Lafayette, Indiana 47906 Contact: Marco Amrhein Phone: (765) 464-8997 Web Site: http://www.pcka.com Abstract: Electrical starter/generators (ESGs) have become increasingly complex in design and integration due to significant power demand increases in more electric aircraft initiatives such as the Joint Strike Fighter (JSF). These new ESG systems must provide high performance and high efficiency with limited active cooling availability. In order to satisfy the power demands and harsher environments anticipated in JSF block upgrades or future military and civilian aircraft platforms, new technologies must be investigated that allow significant performance improvements with increased power density and higher operating temperatures. To address these requirements, PC Krause and Associates (PCKA) is developing a new generator technology that removes temperature limitations associated with traditional synchronous generator designs. This new technology, called the ac-field electrical synchronous generator (ACESG), can operate at temperatures of 500 degrees Celsius and beyond without sacrificing output power capability. Being able to operating at such temperatures has significant advantages: 1) active cooling oil with much higher inlet temperatures can be utilized, 2) heat can be radiated and convected into the environment, and 3) direct integration of the ACESG at the turbine engine becomes possible. All these advantages will result in significant reduction of active cooling, thus reducing size and increasing power density of the ESG system. In the Phase I effort, PCKA will utilize high-fidelity electrical, thermal, and mechanical modeling and simulation to design and optimize the ACESG to JSF ESG specifications. Appropriate high-temperature material characteristics will be considered in the design process to ensure a viable design. At the end of the Phase I effort, the goal is to demonstrate the feasibility and capabilities of the ACESG with a detailed assessment of thermal and electrical performance compared to the existing JSG ESG. If the Phase I effort is successful, PCKA will demonstrate a hardware prototype in the Phase II. If successful, PCKA will transition the ACESG technology to DoD programs under Phase III contracts and/or commercial applications. Benefits: The ac-field electrical synchronous generator (ACESG) technology offers many benefits for present military more-electric-aircraft platforms and future initiatives. Specifically in the Joint Strike Fighter (JSF), which is the targeted commercialization opportunity in this SBIR, the advantages of a higher operating-temperature ESG system reduces active cooling requirements (weight and heat flow) for a significant heat source, thus extending operating capabilities of the aircraft. Further, the ACESG technology enables tight frequency control on the stator main windings, thus providing a basis for ICC design and control optimization that can yield improved power quality in the electrical power system. The same benefits apply to other military and civilian aircraft platforms, in combination with additional benefits such as the possibility to integrate the ACESG directly into the high-temperature turbine engine, providing fixed-frequency output at the ACESG main terminals without need of power electronics converter in the main power path, and providing engine-starting capability at zero shaft speed. Thus, the ACESG technology could significantly change the design of electrical power extraction systems in a variety of aircraft platforms. Beyond airborne systems, the ACESG could provide generator solutions in harsh, high-temperature environments for stand-alone diesel-generator sets, marine power systems, and terrestrial vehicles. Return