Design of an Integrated Inductor for 45kW Aerospace Starter-Generator

A close physical and functional integration of passive components is required to make an efficient and power dense overall system. Such power dense systems are a prerequisite in aerospace and marine applications. This paper presents a design of an integrated rotor-less inductor for the application of a 45kW aerospace starter-generator. The impact of high current density inductor is investigated and compared with traditional EE core inductor in terms of total weight and volume. Both inductors are sized using area product approach and its design parameters are validated using finite element analysis. Comparative analysis between the traditional EE core and the integrated inductor has shown a significant reduction in total weight and volume. The total weight ofthe integrated inductor is reduced by 55.4% whereas the total volume is reduced by 52.7% when compared to traditional air cooled EE core inductor.