{"id":{"repo_id":"mit","oai_identifier":"oai:dspace.mit.edu:1721.1/153873"},"canonical_url":"https://search.dev.ndltd.org/etd/mit/oai:dspace.mit.edu:1721.1/153873","repository":{"repo_id":"mit","name":"MIT","base_url":"https://dspace.mit.edu/oai/request"},"display":{"title":"Modeling, Manufacturing, and Experimental Validation of an Electric Machine for Aircraft Propulsion","abstract":"The work presented in this thesis is part of an effort at MIT to develop a 1-MW electric machine which achieves the specific power necessary for hybrid-electric aviation: 13 kW/kg [1]. The models for torque and core loss used in the design of the 1-MW machine are revised and expanded based on experimental results obtained from a partially-manufactured prototype to guide the design of future high specific-power electric machinery. To calculate the torque produced by the machine, the air-gap field created by a segmented Halbach array rotor is derived from Maxwell’s Equations. The closed-form solution for the air-gap field matches Finite Element Analysis (FEA) to within 1% and experimental data from the manufactured prototype to within the tolerance of the experiment. A method for modeling a slotted stator as a smooth cylinder with a surface current is applied to the stator of the 1-MW machine, and the average torque and torque ripple are calculated using the Lorentz-Kelvin force density. The analytical torque calculation computes 100,000 times faster than 2D FEA (0.56 ms vs. 44 s), and matches FEA to within 1.2%, making it ideal for initial machine design. An experimental procedure is developed to measure the core loss and B-H curve of an iron lamination stack. This procedure is applied to various toroid samples and a stack of slotted stator laminations. A conventional lamination bonding process is found to raise core loss by 20% for 0.1-mm iron-cobalt laminations. An alternative stator-core manufacturing process, which results in no impact on core loss, is identified and experimentally verified. Based on the measured core loss of a stack of stator laminations, the 1-MW prototype is expected to remain within the thermal limits imposed by the winding insulation.","abstract_html":"The work presented in this thesis is part of an effort at MIT to develop a 1-MW electric machine which achieves the specific power necessary for hybrid-electric aviation: 13 kW/kg [1]. The models for torque and core loss used in the design of the 1-MW machine are revised and expanded based on experimental results obtained from a partially-manufactured prototype to guide the design of future high specific-power electric machinery. To calculate the torque produced by the machine, the air-gap field created by a segmented Halbach array rotor is derived from Maxwell’s Equations. The closed-form solution for the air-gap field matches Finite Element Analysis (FEA) to within 1% and experimental data from the manufactured prototype to within the tolerance of the experiment. A method for modeling a slotted stator as a smooth cylinder with a surface current is applied to the stator of the 1-MW machine, and the average torque and torque ripple are calculated using the Lorentz-Kelvin force density. The analytical torque calculation computes 100,000 times faster than 2D FEA (0.56 ms vs. 44 s), and matches FEA to within 1.2%, making it ideal for initial machine design. An experimental procedure is developed to measure the core loss and B-H curve of an iron lamination stack. This procedure is applied to various toroid samples and a stack of slotted stator laminations. A conventional lamination bonding process is found to raise core loss by 20% for 0.1-mm iron-cobalt laminations. An alternative stator-core manufacturing process, which results in no impact on core loss, is identified and experimentally verified. Based on the measured core loss of a stack of stator laminations, the 1-MW prototype is expected to remain within the thermal limits imposed by the winding insulation.","abstract_has_math":false,"creators":["Andersen, Henry"],"institution":"Massachusetts Institute of Technology","degree_name":"Master","degree_level":null,"degree_discipline":null,"degree_department":"Massachusetts Institute of Technology. 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The models for torque and core loss used in the design of the 1-MW machine are revised and expanded based on experimental results obtained from a partially-manufactured prototype to guide the design of future high specific-power electric machinery. To calculate the torque produced by the machine, the air-gap field created by a segmented Halbach array rotor is derived from Maxwell’s Equations. The closed-form solution for the air-gap field matches Finite Element Analysis (FEA) to within 1% and experimental data from the manufactured prototype to within the tolerance of the experiment. A method for modeling a slotted stator as a smooth cylinder with a surface current is applied to the stator of the 1-MW machine, and the average torque and torque ripple are calculated using the Lorentz-Kelvin force density. The analytical torque calculation computes 100,000 times faster than 2D FEA (0.56 ms vs. 44 s), and matches FEA to within 1.2%, making it ideal for initial machine design. An experimental procedure is developed to measure the core loss and B-H curve of an iron lamination stack. This procedure is applied to various toroid samples and a stack of slotted stator laminations. A conventional lamination bonding process is found to raise core loss by 20% for 0.1-mm iron-cobalt laminations. An alternative stator-core manufacturing process, which results in no impact on core loss, is identified and experimentally verified. Based on the measured core loss of a stack of stator laminations, the 1-MW prototype is expected to remain within the thermal limits imposed by the winding insulation."]},{"key":"dc:description.degree","label":"Dc Description Degree","values":["M.Eng."]},{"key":"dc:title","label":"Title","values":["Modeling, Manufacturing, and Experimental Validation of an Electric Machine for Aircraft Propulsion"]}]}],"canonical_facts":{"dc:contributor.advisor":["Lang, Jeffrey H."],"dc:contributor.department":["Massachusetts Institute of Technology. Department of Electrical Engineering and Computer Science"],"dc:creator":["Andersen, Henry"],"dc:date.accessioned":["2024-03-21T19:12:37Z"],"dc:date.available":["2024-03-21T19:12:37Z"],"dc:date.issued":["2024-02"],"dc:description.abstract":["The work presented in this thesis is part of an effort at MIT to develop a 1-MW electric machine which achieves the specific power necessary for hybrid-electric aviation: 13 kW/kg [1]. The models for torque and core loss used in the design of the 1-MW machine are revised and expanded based on experimental results obtained from a partially-manufactured prototype to guide the design of future high specific-power electric machinery. To calculate the torque produced by the machine, the air-gap field created by a segmented Halbach array rotor is derived from Maxwell’s Equations. The closed-form solution for the air-gap field matches Finite Element Analysis (FEA) to within 1% and experimental data from the manufactured prototype to within the tolerance of the experiment. A method for modeling a slotted stator as a smooth cylinder with a surface current is applied to the stator of the 1-MW machine, and the average torque and torque ripple are calculated using the Lorentz-Kelvin force density. The analytical torque calculation computes 100,000 times faster than 2D FEA (0.56 ms vs. 44 s), and matches FEA to within 1.2%, making it ideal for initial machine design. An experimental procedure is developed to measure the core loss and B-H curve of an iron lamination stack. This procedure is applied to various toroid samples and a stack of slotted stator laminations. A conventional lamination bonding process is found to raise core loss by 20% for 0.1-mm iron-cobalt laminations. An alternative stator-core manufacturing process, which results in no impact on core loss, is identified and experimentally verified. Based on the measured core loss of a stack of stator laminations, the 1-MW prototype is expected to remain within the thermal limits imposed by the winding insulation."],"dc:description.degree":["M.Eng."],"dc:identifier.uri":["https://hdl.handle.net/1721.1/153873"],"dc:publisher":["Massachusetts Institute of Technology"],"dc:rights":["In Copyright - Educational Use Permitted","Copyright retained by author(s)"],"dc:rights.uri":["https://rightsstatements.org/page/InC-EDU/1.0/"],"dc:title":["Modeling, Manufacturing, and Experimental Validation of an Electric Machine for Aircraft Propulsion"],"dc:type":["Thesis"],"thesis:degree_name":["Master","Master of Engineering in Electrical Engineering and Computer Science"]},"updated_at":"2026-07-22T22:20:59Z"}