Delft University of Technology Design of high-torque-density synchronous drives for propulsion of rotary-wing aircraft Sanabria von Walter, Christian DOI 10.4233/uuid:fc614c24-420a-45f2-8d47-78e9dd4c750b Publication date 2016 Document Version Final published version Citation (APA) Sanabria von Walter, C. (2016). Design of high-torque-density synchronous drives for propulsion of rotary- wing aircraft. https://doi.org/10.4233/uuid:fc614c24-420a-45f2-8d47-78e9dd4c750b Important note To cite this publication, please use the final published version (if applicable). Please check the document version above. Copyright Other than for strictly personal use, it is not permitted to download, forward or distribute the text or part of it, without the consent of the author(s) and/or copyright holder(s), unless the work is under an open content license such as Creative Commons. Takedown policy Please contact us and provide details if you believe this document breaches copyrights. We will remove access to the work immediately and investigate your claim. This work is downloaded from Delft University of Technology. For technical reasons the number of authors shown on this cover page is limited to a maximum of 10. Design of High-Torque-Density Synchronous Drives for Propulsion of Rotary-Wing Aircraft Design of High-Torque-Density Synchronous Drives for Propulsion of Rotary-Wing Aircraft PROEFSCHRIFT ter verkrijging van de graad van doctor aan de Technische Universiteit Delft, op gezag van de Rector Magnificus prof.ir. K.C.A.M. Luyben, voorzitter van het College voor Promoties, in het openbaar te verdedigen op woensdag 18 mei 2016 om 15.00 uur door Christian David SANABRIA von WALTER Master of Science in Elektrotechnik, Technische Universität Hamburg-Harburg geboren te Bogotá, Colombia Dit proefschrift is goedgekeurd door de promotor: Prof.dr.-Eng. J.A. Ferreira Copromotor: Dr.ir. H. Polinder Samenstelling promotiecommissie: Rector Magnificus, voorzitter Prof.dr.-Eng. J.A. Ferreira, Technische Universiteit Delft, promotor Dr.ir. H. Polinder, Technische Universiteit Delft, copromotor Prof.dr. R. Nilssen, Norges Teknisk-Naturvitenskapelige Universitet Dr. A. Gangoli Rao, Technische Universiteit Delft Prof.dr.ir. A.H.M. Smets, Technische Universiteit Delft Prof.dr. E. Lomonova, Technische Universiteit Eindhoven Prof.dr. J.J. Smit, Technische Universiteit Delft This research was supported by the Airbus Group and the European Union's Seventh Framework Program (FP7) through the Clean Sky Joint Technology Initiative Printed by Gildeprint Drukkerijen, Enschede, The Netherlands ISBN 978-94-6186-648-6 Copyright © 2016 by Christian Sanabria von Walter All rights reserved. No part of the material protected by this copyright notice may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system without permission from the author. to the Sanabria von Walter and Robl families Acknowledgements These pages are the culmination of a journey, the journey of a curious child trying to figure out how technology works. In 2004 this curiosity led me to Germany, the country that I now call home, and where in 2010 I began my doctoral research at EADS Innovation Works, now Airbus Group Innovations (AGI) in Munich. In this quest, I was privileged enough to count with the support and guidance of the Electrical Power Processing (EPP) group of the Delft University of Technology (TU Delft) in The Netherlands. These particular circumstances brought me in contact with many different individuals from many different backgrounds from which I profited enormously in my personal and professional growth. Some of them, through their contributions, influence and example have been determinant in the development of who I am today. For their support and guidance I am ever grateful. In first place, I would like to thank my AGI supervisor, Markus Christmann, whose support and fairness were vital for the realization of this work. It was because of his guidance and trust that I was able to come to a successful conclusion of this research. As my superior he always found the best balance between the objectives of his team and those of my research. For this I will always be in debt with him. Equally important during this time was my TU Delft co-promoter and supervisor, Henk Polinder. He took me in as his PhD candidate and offered me nothing but the best academic guidance. His advice and friendship always accompanied and motivated me to persevere and see this project through. His involvement in my work as a professional, friend and human being were a true privilege. My gratitude also goes out to my TU Delft promoter, Prof. Braham Ferreira. He always asked the right questions and highlighted the key aspects that insured the quality and sharpness of my work. To my fellow doctoral candidates Johannes Kirn, Tim Hilden and Sebastian Seemann: I thank you for your contributions and friendship. We always worked in an atmosphere of comradeship characterized by its positive energy. That our respective fields were different from one another was never a disadvantage but an immediate source of knowledge, fresh ideas and points of view. I specially thank Johannes Kirn who was crucial in my understanding of structural and materials engineering, a very important aspect in my research. He was always unconditional and willing to offer his time and patience to answer my questions. I also thank my AGI team colleagues Alexander Kaiser, Gerhard Steiner, Stefan Friedl and Konrad Lentner whose sound technical knowledge was an invaluable help more than i once. In particular I would like to thank Frank Hermle, for his active support and participation in the successful development of the experimental setup, and Michael Hofmann, a key person in the planning of the next steps of my career. At this point I would like to make special mention of the people who are personally closest to me and who have a very special place in my life. My deepest gratitude and love goes to Oswald and Ingrid Robl. They constitute what I have come to call my family in Germany, took me into the core of their home like a son and entrusted me with their most valuable treasure. They have been by my side since before the beginning of this project and have given me their unconditional and unmatched support. It is very difficult to imagine how any of this would have come to be without them. To my mother and father: physical separation over long periods of time has not been easy for any of us. But you can be sure that your love and memory are much more powerful than any uncertainty, fear and solitude that might unsettle me. It is this love what has always given me the strength to keep pursuing, to keep persevering, to keep dreaming. To you I simply owe my existence. To Gabriela: no one has been most affected by distance and separation more than you have. It is my dream not to be absent anymore and I will never cease to work for this ideal, I will never cease working for your well-being. I dedicate this achievement also to you; it takes us one step closer to that dream. To Pablo: the journey has been longer than what we planned, but at last we are seeing the light at the end of the tunnel, this time brighter than ever. This is only because you were always there to remind me why we came here, to remind me in which direction we are going, to remind me there was still some road ahead of us. Whatever the future may bring, only one thing is certain: you are the only one I could always call “my family” here, you are my blood, you are my truest friend. This achievement is as much yours as it is mine. Finally, to the commander in chief of my “state of love and trust”: Christina. You seem so fragile, yet you seem to be the only one able to endure a dark day with me. I have simply lost count of the lessons you have repeatedly taught me in matters of love, humility and respect. Thank you for your resilience and for your love, thank you for enduring this time with me. Nothing could have ever prepared me for the happiness and greatness you have brought into my life. I am more than looking forward to spending the rest of my life with you. Christian Sanabria von Walter Munich, April 2016 Table of Contents Acknowledgements ................................................................................................................ i Table of Contents ................................................................................................................. iii Symbols and Abbreviations ................................................................................................ ix Chapter 1 Introduction .................................................................................................... 1 1.1 General Motivation .................................................................................................. 1 1.2 Conventional and Alternative Aircraft Propulsion .................................................. 2 1.3 Problem description ................................................................................................. 4 1.3.1 State of the art of electrical machines .............................................................. 4 1.3.2 Research Question ............................................................................................ 6 1.3.3 Thesis Objectives ............................................................................................. 7 1.3.4 Experimental Setup: ........................................................................................