Multi-Objective Design Optimization of Electric Aircraft Propulsion Power Converters

Aircraft electrification is an emerging technology to enable net-zero emissions for global aviation. When designing an electric aircraft propulsion system, multiple objectives are desirable for the power electronic converters such as concurrently high efficiency and high power density. This requires computationally efficient design optimization. The approach proposed in this work aims to optimize an electric aircraft propulsion converter on the basis of high power density, high efficiency, high reliability, and low cost. This design methodology has been examined and a candidate solution set has been generated for a back-to-back voltage source converter rated at 1 MW with a DC-link voltage of 2.4 kV. Using a selection of commercially available power components, accurate calculations, including cost, have been conducted for the 17,107,272 solutions in just 20 minutes approximately. Of the 7,930 designs in the Pareto front when using the objectives of power density, cost, efficiency, and reliability, the optimal performance on each goal for the propulsion power converter system is 11.151 kW/kg, $22.03/kW, 98.302%, and 1,642 FIT, respectively.