A TEAM FROM THE UNIVERSITY OF ILLINOIS IN PARTNERSHIP WITH AUTOMATED DYNAMICS AND UNITED TECHNOLOGIES RESEARCH CENTER HAS DESIGNED AND BUILT A 1MW HIGH SPEED HIGH FREQUENCY MOTOR AND DRIVE UNDER NASA GRANT NUMBER: NNX14AL79A. IN THE FOUR-YEAR PROJECT THE TEAM HAS DEVELOPED ALL THE KEY COMPONENTS FOR THIS MOTOR: HIGH SPEED ROTOR ASSEMBLY WITH HALBACH MAGNET ARRAYS DISTRIBUTED FORM-WOUND COILS MADE WITH HIGH FREQUENCY LITZ WIRES A NICKEL IRON YOKE AN ALUMINUM HEAT SINK A BEARING SYSTEM ETC. ACCORDING TO THE ORIGINAL PLAN THE FULL MOTOR ASSEMBLY SHOULD HAVE BEEN COMPLETED IN FALL 2018 AND SENT FOR SUBSEQUENT THE SYSTEM PERFORMANCE TESTING AT COLLINS AEROSPACE TEST FACILITY IN ROCKFORD IL. THE PREPARATION WORK FOR THE TESTING BEGAN IN NOVEMBER 2018. JOINT MEETINGS BETWEEN THE UNIVERSITY OF ILLINOIS TEAM AND COLLINS AEROSPACE ENGINEERS HAVE BEEN HELD TO DISCUSS DETAILED PLANS SUCH AS DRIVETRAIN CONFIGURATION AND EQUIPMENT PROCUREMENT. HOWEVER THE RARE-EARTH MAGNET VENDOR ARNOLD MAGNETIC TECHNOLOGIES MADE MISTAKES IN THE ASSEMBLY LEADING TO INCORRECT MAGNET ORIENTATIONS. THE ASSEMBLED ROTOR HAD TO BE SENT BACK TO ARNOLD IN JANUARY 2019 FOR DISASSEMBLY AND RE-BUILD. DUE TO THE DIFFICULTIES IN HANDLING HIGH ENERGY DENSITY RARE-EARTH MAGNETS THE CORRECTION PROCESS WILL TAKE APPROXIMATELY FOUR MONTHS. WITH THE PLANNED TESTS PERFORMED SUCCESSFULLY THE DESIGN CONCEPT AND FABRICATION METHODS PROPOSED IN THE 1 MW HIGH SPEED HIGH FREQUENCY MOTOR PROJECT WILL BE VALIDATED. ONE MW ACTIVE POWER WILL BE GENERATED IN THE GENERATING-MODE TESTS THUS ACHIEVING THE FULL CAPACITY OF THE MOTOR AND EFFICIENCY MEASUREMENTS WILL BE MADE. THE PRIMARY TARGET OF THE MACHINE S SPECIFIC POWER IS GREATER THAN 13 KW/KG AND THE EXPECTED EFFICIENCY AT RATED CONDITION IS 96- 97%. THE INTEGRITY AND FUNCTIONALITY OF THE MECHANICAL STRUCTURE COOLING SYSTEM AND INSULATION SYSTEM OF THE MACHINE WILL BE VERIFIED. THE TOTAL LOSS WILL BE MEASURED AND MACHINE ENERGY EFFICIENCY OVER VARIOUS LOADING CONDITIONS WILL BE OBTAINED. MOTORING-MODE TESTS WILL BE ABLE TO DEMONSTRATE THE CAPABILITY OF VARIABLE SPEED OPERATION FOR THIS MACHINE.
$59,996FY2020National Aeronautics and Space AdministrationNASA
University Of Illinois