Recent developments in aircraft starter/generator and its embedding technology
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摘要:
航空起动/发电机是现代多电第二动力系统的关键核心。对起动/发电机的常用发电机类型进行了概述，按起动/发电机是否内置于发动机中进行分类并分别对两大类起动/发电机的发展现状进行简介，讨论了内置式起动/发电机的结构布置方案。综合分析了高效散热技术、轻质高效发电机技术、强容错发电机技术、高温发电机技术、高性能变流技术这五项起动/发电机关键技术。展望了起动/发电机结构集成化、设计协同化、任务多样化的发展趋势。最后指出，各主要类型发电机在起动/发电机应用中均有不可替代的地位，起动/发电机的内置化仍需要在强散热、高功率密度、强容错以及耐高温等自身重要技术指标上取得突破。
Abstract:Aircraft starter/generator is a core component of the modern more electric aircraft (MEA) secondary power system. An overview of the mostly used generator type for starter/generator system was presented. Starter/generators were categorized according to whether the generator was embedded within the engine, and the development status of both categories was reviewed, together with typical structural layout schemes for embedded starter/generators. Five key technologies of starter/generator were analyzed: efficient cooling technology, light-weight and high-efficiency generator technology, fault-tolerant generator technology, high-temperature-tolerant generator technology and high-performance converter technology. Evolving trends towards structural integration, collaborative design and multi-task were envisioned. Result show that, common types of generators play essential roles in the application of starter/generators, and the realization of fully embedded starter/generators hinges on further breakthroughs in key figures of merit such as thermal management, power density, fault tolerance, and high-temperature endurance.
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图 1 F135附件传动机匣及其配套160 kW WFS S/G
Figure 1. Accessory gearbox of F135 engine and associated 160 kW WFS S/G
图 7 汉胜公司与通用电气公司研制的250 kW SR S/G
Figure 7. 250 kW SR S/G developed by Hamilton Sundstrand and General Electric
图 9 南京航空航天大学与涡轮院合作研制的200 kW SR S/G
Figure 9. 200 kW SR S/G developed by Nanjing University of Aeronautics and Astronautics and Sichuan Gas Turbine Establishment
图 10 双转子涡扇发动机的集成发电机结构
Figure 10. Structure of embedded generator in two-spool turbofan engine
图 11 AFRL发动机低压转子轴功率提取试验平台
Figure 11. Low-pressure spool power extraction experimental platform in AFRL
图 12 三转子涡扇发动机的集成发电机结构
Figure 12. Structure of embedded generator in three-spool turbofan engine
图 27 四川燃气涡轮研究院与南京航空航天大学合作研制的多电涡喷样机
Figure 27. More-electric turbojet engine developed by Nanjing University of Aeronautics and Astronautics and Sichuan Gas Turbine Establishment
图 28 南京航空航天大学与航空工业电源合作研制的内置式SR S/G
Figure 28. Embedded SR S/G developed by Nanjing University of Aeronautics and Astronautics and Shanxi Aero Electric Company, Limited
图 32 机壳循油和定子浸油冷却方案示意图
Figure 32. Schematic diagram of oil-jacket and oil-immersed cooling
图 34 机壳喷油和空心轴喷油示意图
Figure 34. Schematic diagram of stator spray cooling and rotor spray cooling with hollow shaft
表 1 主流航空起动/发电机类型对比
Table 1. Comparison of common aircraft starter/generators
起动/发电机类型 优势 劣势 WFS S/G · 调压控制简单，仅需小容量功率变换器进行直流励磁调节；
· 发电运行时无需转子位置信号；
· 技术成熟度高。· 转子结构复杂且发热量大，需要复杂的转子
冷却结构，难以用于高温、高速应用；
· WFS S/G的起动控制需要转子位置信号、特殊的
交流励磁方案和大容量起动逆变器；
· 大感值励磁绕组不利于提高负载响应速度。PMS S/G · 功率密度高；
· SmCo永磁体和合金护套增强转子
耐高温能力（300～350℃）；
· 永磁体损耗较易抑制，转子损耗低；
· 易于实现长气隙设计，允许加厚护套
从而适应高速运行；
· 起动功能易于集成。· 励磁磁势固定，需要大容量功率变换器或额外的
定子绕组进行调压；
· 必需特别的手段来应对绕组部分或整体短路故障；
· 系统运行依赖于转子位置信号；
· 合金护套损耗需要关注，复合纤维护套损耗低
但耐温能力差（<200℃）；
· 永磁体工作点须综合温度和过载进行校核。SR S/G · 转子结构最简单，易于实现高速运行，具备最强高温适应性；
· 定子集中绕组，结合特有功率变换器
从而具备强容错能力；
· 起动功能易于集成。· 转矩脉动大；
· 转子的铁芯损耗和风阻损耗较大；
· 性能对气隙长度敏感；
· 系统运行依赖于转子位置信号；
· 脉冲相电流决定系统必需高电流容量器件和
大容量母线电容。
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表 2 外置式起动/发电机汇总
Table 2. Summary of external starter/generators
类型 研制方 功率 转速/（r/min） 质量/kg 冷却方式 参考文献 WFS S/G 汉胜 250 kVA 16000 92 机壳循油、
空心轴喷油[5] 225 kVA 55.7 霍尼韦尔 150 kVA 柯林斯 225 kVA 14000 [22] 赛峰 200 kVA 16000 90 [23] 汉胜 160 kW [7] 通用电气 160 kW 32490 机壳、转子循油 [24] 南京航空航天大学 120 kW 8000 52 自通风 [25] PMS S/G 通用电气 150 kVA 21000 机壳循油后喷油 [26] 60 kVA 30000 27.9 机壳、空心轴循油 [27] 40 kVA 26250 17.9、9.1^ [28] 谢菲尔德大学 100 kW 26584 22.8、12.2^ 定子浸油、转子强迫通风 [29-30] 诺丁汉大学 45 kW 32000 定子浸油 [31-32] 250 kW 24000 56.7^ [33] PMASynR S/G 北京航空航天大学 45 kW 24000 13 机壳循油后喷油、端盖喷油 [34-35] SR S/G 汉胜 250 kW 25558 59.4、38.9^ 机壳、空心绕组、转子循油 [36-39] 南京航空航天大学 200 kW 20700 机壳循油、壳体内强迫通风 华中科技大学 150 kW 20000 机壳、转子循油 [40-41]
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表 3 内置式起动/发电机、发电机汇总
Table 3. Summary of embedded starter/generators and generators
类型 研制方 功率 转速/（r/min） 质量/kg 冷却方式 参考文献 WFSG 普惠 30 kVA 11100 24.4 空心轴喷油 [56] 赛峰 75 kVA 8200 机壳、转子循油 [53, 57-58] PMS S/G 通用电气 120 kVA* 17600 34^ 机壳循油、转子油雾冷却 [47] 普惠 31000 [59] 赛峰 150 kW+ 15000 88^ 定子浸油、空心轴循油 [23] 罗罗 51000 强迫通风 [60] 霍尼韦尔 80 kW 59000 滑油冷却 [7, 61] 赛峰 50 kW 56000 19 强迫通风 [23] 诺丁汉大学 20 kW 14200 2.8^ 定子浸燃油 [62] PMSG 罗罗 250 kW 3100 183^ 强迫通风 [49, 63-65] 乌法国立航空大学 120 kW 60000 28 强迫通风 [66] SR S/G 通用电气 32 kW 48000 机壳、空心轴循油、
定子槽内管路循油[67-68] 汉胜 30 kW 46850 7.7^ 机壳、空心轴循油 [69] 通用电气 375 kW* 15460 33.6^ 机壳、空心绕组、空心轴循油 [48, 70] 霍尼韦尔 125 kW* 60000 强迫通风 [54, 71] 汉胜 125 kW 60000 自通风 [72-73] 霍尼韦尔 15 kW 60950 强迫通风 [6] 谢菲尔德大学 100 kW+ 13500 强迫通风 [52, 74] 15 kW+ 30000 11.3^ [75] 柏林工业大学 30 kW 50000 定子循水（样机） [76] 南京航空航天大学 6 kW 40000 强迫通风 125 kW 46000 机壳循油、空心轴喷油 西北工业大学 3 kW+ [77] SRG 赛峰 150 kW 10000 105 机壳、空心轴循油 [78] DSE S/G 南京航空航天大学 100 kW 63000 42 机壳循油、空心轴喷油 [16, 79] 27 kW 24000 自通风 [80] 150 kW 13000 105.6、47.8^ 机壳循油、转子强迫通风 [17] 12 kW+ 15000 [81]
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