HPEM

Development of key technology components for high performance electric motors

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 Obiettivo del progetto (Objective)

'HPEM technological research program proposes the integration of emerging permanent magnet motor and position sensor technologies in high power density, fault tolerant actuator designs which could be an integral part of a rotorcraft swashplate electromechanical actuation system with superior dynamic response and fault ride through capability. Innovative permanent magnet and insulating material technologies, involving particular Neodymium alloy permanent magnet materials with small substitution for iron by Cobalt enabling to substantially improve high temperature performance as well as specially enameled winding wires treated through vacuum pressure impregnation techniques, respectively, in conjunction with design optimization methodologies based on embedded permanent magnet topologies are going to be applied at the program operational level.. The HPEM project is divided in three Work Packages. WP1 is oriented to the better understanding of the specifications and the validation plan through motor and sensor preliminary design and pilot hardware manufacturing. WP2 is the project core development that covers critical design of motor and sensor modules resulting in the proposal of two alternative configurations and delivery of respective prototypes. Embedded permanent magnet and flux-switching topologies as well as photo-diode, photo-transistor and Hall effect sensor formulations are going to be evaluated on the basis of performance and reliability requirements. Finally, WP3 covers manufacturing and testing of the remaining twelve prototypes to be delivered. During this WP all specific test benches will be developed so that the technological readiness level expected will be certified. HPEM project success could allow safer aeronautic transports as well as size and weight reduction of generation equipment. Significant reduction in maintenance and overall environmental impacts is expected to be achieved too.'

Introduzione (Teaser)

Replacing hydraulic and pneumatic parts with electrical ones promises increased reliability and decreased weight for the aerospace sector. Scientists are delivering an improved electrical control system for helicopter rotors to meet the challenge.

Descrizione progetto (Article)

Novel actuator designs for transferring helicopter control signals to the main rotor blades could improve high-temperature performance and reduce weight and emissions. Safer air transport with reduced maintenance and lower fuel consumption will enhance the competitiveness of the EU aerospace industry.

EU-funded scientists working on the project 'Development of key technology components for high performance electric motors' (HPEM) are exploiting new permanent magnet motor and position sensor technologies. The electrically powered actuators are targeted as integral components of an electromechanical system to control the swashplate of the main rotor of a medium-sized rotorcraft. These systems are expected to yield high power density and improved fault tolerance.

During the first reporting period, the team conducted an extensive literature review of existing technologies, paying special attention to high-temperature behaviour and accumulation of stress. This was complemented by numerical analyses and simulations. Development of a test bed has enabled assessment of promising new materials with potentially better performance.

Results of the literature survey and experimental and theoretical investigations led to design of the individual motor and sensor systems. Scientists then defined the overall packaging and interconnections, internally between the sensor and motor components as well as the interface with external instrumentation. The team has now developed the protocol for upcoming laboratory testing of the final motor topology.

HPEM electrical actuator technology for helicopter rotor blade control addresses EU goals of more electric, more reliable and greener air transport. Integrating electrically powered speed and position sensors will also enhance capabilities for engine monitoring and diagnostics. The team is making sure to spread the word to industry, certification bodies, national policymakers, schools and EU citizens. By project end, the ground should be fertile for HPEM outcomes to take flight.