Measurement and Analysis of Generator bearing Loads and Efficiency with Validation

The aim of the MAGLEV project is to develop a new generator prototype for aerospace applications, which is designed for high speeds, while minimizing shaft tilting, bearing vibrations and bearing loads. By increasing energy efficiency and reliability, an important contribution will be made to improving the performance of aircraft generators.

A new intelligent control strategy based on measurement data during operation minimizes the bearing loads and slip losses of the generator prototype. The displacement and vibration measurement data serve as the controlled variable for determining the bearing loads. The kinematic condition of the bearing is determined by high-precision measurement of the cage and shaft speed. The load conditions, which can also affect the generator in practical operation, are generated by a load emulator developed in this project. Both the measuring system and the load emulator are integrated into the generator prototype and the control system. The newly developed control system will be tested and validated on the generator prototype. An additional adjustment is carried out on bearing test benches to measure the friction torque. The operating condition of the generator bearings is simulated on the test bench with regard to bearing load, kinematics and lubrication in order to determine the resulting power losses and to assess the success of the control strategy.