New Cooling Technology to Increase Aircraft Generators Power Rating

Period of Performance: 11/07/2001 - 05/07/2002


Phase 1 SBIR

Recipient Firm

Innovative Power Solutions, LLC
373 South Street
Eatontown, NJ 07724
Principal Investigator


Commercial and military aircrafts are kept in service for longer periods than originally intended, and many aircrafts designed and built in the 60's and 70's (e.g., CH-46, 737), are still in service with no immediate replacement plan. At the same time, avionic equipment and advanced weapon systems were developed, which require much more electric power than was originally perceived when the aircrafts were designed. Installing new generators, which provide additional electric power is limited by the available space and existing aircraft interfaces that cannot be changed, since it will have a significant effect on engine and accessory gearbox design and other aircraft systems. It would be very beneficial if a new generator with 30% to 50% more power, with same envelope and installation interfaces, could replace the existing aircraft generator without changing any aircraft systems/interfaces. A way to increase power output and maintain weight and size is to improve the cooling system, so that higher power densities could be accomplished without effecting generator life and reliability. This proposal, geared for the P-3 aircraft, is for a generator with an improved air cooled design, which provides at least 33% more power output, in the same envelope without requiring any aircraft changes. The cooling technology developed under this effort will have widespresd application in generators and transformers. Improved heat removal will allow for an increase the power density of electromagnetic devices, which will result in smaller size and weight or increased power output. The results of this effort will benefit the airlicraft industry, both military and commercial, that is constantly looking for more electrical power at a lower power to weight ratio. The results of this program will also be beneficial to consumer products and industrial applications because of improvements in thermal efficiency and reliability.