High Frequency Permanent Magnet Generator for Pulse Density Modulating Converters

This thesis describes an investigation of high frequency permanent magnet generators for use in a novel power generation system for aerospace applications. The system consists of a high frequency generator (in the 10s of kHz range) which feeds a full-wave rectifier to produce to a high frequency pulse train as input to a pulse-density modulated soft-switched converter.
Various topologies of flux-switching, flux-reversal and Vernier machines are investigated using electric-circuit coupled finite element analysis. Having demonstrated the limitations of these topologies, a comprehensive design study into a single-phase, surface mounted permanent magnet machine based on a single turn serpentine winding is described. This study covers both internal and external rotor machines with pole numbers of 192 and 96 which correspond to generator fundamental frequencies of 32kHz and 16kHz at the rated speed of 20,000rpm. Several aspects of the machine design are optimised through extensive use of finite element modelling, including mechanical analysis of the rotor containment. This study includes a detailed consideration of iron loss, including consideration of iron powder based cores. This study has resulted in a down-selected design based on a low permeability but high resistivity powdered iron core.
The manufacture of a demonstrator is described including the need to re-design the machine to employ ultra-thin Nickel Iron laminations because of the difficulties encountered in the machining of a powdered iron core. The performance of this Nickel Iron variant is investigated and a final design established. The numerous challenges involved in manufacturing this novel machine are described.