可靠性约束下多电飞机飞控系统高功率密度电机设计理论与方法研究

Nowadays, the aircraft moves towards the more electric aircraft. One of the key technologies is to replace the traditional bulky hydraulic actuation system with distributed compact electric powered actuation system for flight control surface. The bottleneck technique of such system is the high power density design under the constraint of extreme high reliability requirement. The subject of this research is the electrical motor for this electric powered actuation system. The design measures to improve the power density and reliability are usually conflict with each other, therefore it is a great challenge to obtain high reliability and high power density simultaneously. To overcome this problem, the coupled multi-physic field analysis based on accurate material characteristics model was employed. The failure rate model of the motor was built using the combined simulation and reliability experiment results. The failure rate was adopted as the constraint, together with the optimization techniques, the design and control parameters were coordinated, which bring forward the breakthrough in technologies such as fault tolerant motor topology, losses suppression and allocation, high efficient thermal design and management, high speed rotor structure design. Eventually, a novel design method of high power density motor under the constraint of reliability will be formed, so as to lay solid theoretic and technical foundation for these types of motors.

多电飞机是目前国内外研究的热点之一，其核心技术之一是飞控系统中采用电力作动器取代传统的集中油源的液压作动器。飞控系统驱动电机的特殊之处在于极高的可靠性要求，如何在满足飞机装备可靠性要求的基础上实现高功率密度是其关键技术瓶颈。本项目以电力作动器驱动电机为研究对象，针对功率密度与可靠性的设计参数相互制约，难以兼顾的难点，从基于精准材料特性模型的多物理场耦合分析入手，从仿真分析与可靠性试验研究两个方面建立电机的失效率模型，以此为约束，引入优化算法，通过设计与控制因素的协同优化，突破容错冗余结构设计、损耗的抑制与分配、高效热管理与热设计、高速转子结构设计等关键技术，形成可靠性约束下高功率密度电机设计理论与方法，为其工程应用提供理论基础与技术支撑。

绿色多电飞机是航空业发展的必然趋势，其核心技术之一是飞控系统中采用电力作动器取代传统的集中油源的液压作动器。在满足飞机装备苛刻可靠性要求的基础上实现高功率密度是其关键技术瓶颈。本项目针对电液作动器驱动电机内部充油的特点，全面梳理了充油电机相关的基础理论与设计方法，搭建了材料、部件的特性测试平台，提出了基于改进JA动态磁滞模型的非正弦供电损耗计算模型和流体粘滞损耗模型；建立了电磁转矩、定子铁耗、转子铁耗和永磁体涡流损耗随温度变化的函数，并通过用户定义函数，实现多场的直接耦合；通过电、热应力加速退化实验，根据Miner的累积损伤定律获得了变负载下的寿命预测模型。以永磁电机的功率密度和绝缘热寿命最大化为目标，采用了NSGA-II多目标进化优化算法，建立了面向可靠性的高功率密度电机多目标优化设计方法。以某型飞机襟翼作动器驱动电机为应用对象，研制了一台18kW, 峰值转速15000rpm, MTTF 20000小时的永磁电机样机，满足作动器驱动性能、安装空间限制和可靠性约束的要求，并通过综合实验验证了理论模型与设计方法。上述成果申请发明专利8件，其中5件已授权；发表高质量论文10篇，其中SCI论文8篇。上述方法可用于航空航天等可靠性要求极高的领域，为飞行器性能的提升提供关键技术支撑。