Multidisciplinary Design and Optimization of High-Speed Hybrid Excitation Starter Generator for Aircraft Power System

In this article, a multidisciplinary optimization design on a high-speed hybrid excitation starter generator (HESG) is presented for aircraft power system, which takes into consideration of electromagnetic and mechanical performances. First, the working mechanism of the axial electromagnetic force is revealed and analyzed. The stator support component of high-speed HESG is optimized to improve the stator stiffness. Then, a new configuration of the high-speed HESG rotor is proposed to improve mechanical strength. The rotor stress analytical model is deduced and compared with the finite element analysis (FEA). In addition, the interference fit and sleeve thickness are optimized to improve the permanent magnet (PM) rotor strength. Meanwhile, the electrically excited (EE) rotor parameters are optimized to improve the EE rotor strength and power density. Besides, the rotor model is obtained and optimized to improve rotor rigidity. The multiple physical field analysis model of optimal high-speed HESG is built. The electromagnetic, mechanical, and modal performances are obtained to validate the effectiveness of the high-speed rotor design. Finally, a high-speed HESG prototype is manufactured and tested, and the measured results show that the output power is up to 63.2 kVA at 8000 r/min.