New Cooling Technology to Increase Aircraft Generator Power Rating

Period of Performance: 12/13/2002 - 12/13/2004


Phase 2 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, 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. The P-3 aircraft is operating at power levels that are continuously above the 60 KVA continuous rating of the generator. Specifically, the 28B95-65 generator is operating at 88 KVA for extended periods of time. Since the generator is exceeding the overload conditions on a regular basis, the life of the generator has been significantly deteriorated. The goal of this program is to develop a generator for the P3 aircraft, which provides 30% to 50% more power, while maintaining the same envelope and installation interfaces. IPS is utilizing both electromagnetic material changes as well as innovative cooling techniques to meet these goals. At the conclusion of this program IPS will have the design to provide a complete generator for replacement of existing units in the field. IPS has the in-house capability to design and build the proposed generator. BENEFITS: Improved cooling techniques developed by IPS for generator cooling has vast potential for applications in virtually all air-cooled generators. The anticipated benefits of efficiently cooling the generator are increased power density and improved reliability. The benefits for improved power density are extremely important in all airborne applications where minimizing weight and size of equipment improve payload capacity.