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

This paper presents a combined electromagnetic and thermal design of integrated inductor, for the application of a 45kW aircraft starter-generator. The inductor is designed at high current density by using the apporach of area product, followed by the finite element analysis, which validates the electromagnetic performance of integrated inductor. The total power losses at 8, 20, and 32kRPM are evaluated in order to investigate the thermal design of a combined starter-generator and integrated inductor system, whilst, achieving the full integration from a thermal management point of view. As both starter/generator and inductor share common cooling configuration; performance of a direct and an indirect cooling options are compared. The direct cooling configuration, based on a semi-flooded design, can lead to a temperature reduction up to 90°C in the most critical components.