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

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.