Design and Testing of a Four-Phase Fault-Tolerant Permanent-Magnet Machine for an Engine Fuel Pump

TLDR

The study presents the design and testing of an aircraft electric fuel pump drive. The drive is a modular, four‑phase, fault‑tolerant permanent‑magnet motor with a Halbach‑array rotor, whose high electric loading is achieved by flooding the motor with aircraft fuel for cooling, and its performance is evaluated through theoretical analysis and tests under normal and fault conditions. Testing shows that fuel‑flooded cooling yields excellent electrical and thermal performance with negligible rotor drag.

Abstract

This paper discusses the design and testing of an aircraft electric fuel pump drive. The drive is a modular, four-phase, fault-tolerant system which is designed to meet the specification with a fault in any one of the phases. The motor employed has a permanent-magnet rotor with the magnets arranged in a Halbach array to maximize the air-gap flux density. Exceptionally high electric loadings are obtained by flooding the entire motor with aircraft fuel, which acts as an excellent cooling agent. Theoretical results are compared with test results gained in conditions approaching those found in an aircraft. Tests are carried out on the unfaulted drive and with one of several fault scenarios imposed. The electrical and thermal performance of the drive is assessed, showing how the flooded fuel cooling has excellent performance without introducing significant drag on the rotor.