EMAS

Electric Motor And Sensor design and manufacture

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 Obiettivo del progetto (Objective)

'EMAS proposes a technological research program enabling to develop, validate and manufacture eight actuators presenting high performance and high reliability for high speed applications under high temperature environment. Such actuators will be capable of producing 5 N.m torque under 10.000 rpm for an environmental temperature of 100 C involving low short circuit current and will be supplied by sine wave power converters. They will present high power density and low mass by conveniently exploiting high energy - high temperature Neodymium alloy permanent magnet materials in conjunction with optimized motor topologies and high speed sensor technologies. The proposed methodology involves three stages devoted to the preliminary actuator design, to the critical actuator design and to the actuator manufacturing and testing activities, respectively. Several technologies will be evaluated at a high temperature level and, then, the best of these technologies will be improved before its integration in the final prototype. The research for motor concept will involve a comparison of permanent magnet machine topologies: internal and surface permanent magnet machine topologies are going to be compared, by means of classical motor analysis and design procedures coupled with numerical magnetic field analysis and simulation software, for their ability to provide low short circuit current and produce sinusoidal flux distribution. Moreover, optical and magnetic position sensors will be compared both on their ability to provide sufficient details on motor position and speed in very low and high speed ranges and their capacity to withstand the required temperature conditions. The criteria analyzed for each candidate architecture are: the integration density level (mass volume), the simplification of interfaces between subassembly, the thermal management performances, the ability for the technologies selected to fulfill any reliability objectives.'

Introduzione (Teaser)

Researchers have developed and tested new designs for the actuators used in aircraft control systems. The new electronic-based systems are lighter and require less maintenance than existing technologies.

Descrizione progetto (Article)

Actuators are the part of the aircraft control system that initiates changes in the position of flaps, rudders and other systems based on the pilot's steering movements. Currently, these systems are often based on hydraulics, which are heavy and need to be serviced regularly.

The EU-funded 'Electric motor and sensor design and manufacture' (EMAS) project assessed, implemented and validated emerging electrical actuation technologies for high-speed, severe-environment aerospace applications. With a research team drawn from leading institutes and manufacturers from several countries, the project assessed various induction motor (IM) and permanent magnet motor (PMM) designs. They then selected the most promising candidates for further industrial development.

Study results showed that PMM is the most favourable current option.

Although the optimum IM configuration presents advantages in terms of lower breaking torque and short-circuit currents, it is larger and heavier than the PMM for the same thermal evacuation ratio.

In addition to developing the prototype manufacturing process, EMAS' other work involved updates to smart electronic sensor and motor platforms for flight control systems. These include new design and simulation software, specialised experimental test benches, magnetic and insulation materials, and high-speed sensor technologies.

The innovative technologies pioneered during EMAS fit in with the modular concept of the next generation of aircraft. These will incorporate more electrics into their systems and promise considerable benefits over current solutions, with greater efficiency and reliability at lower running costs.