Research and Realization of High-Power Medium-Voltage Active Rectifier Concepts for Future Hybrid-Electric Aircraft Generation

In this article, we describe the research and development of a 3 kV active rectifier for a 4 MW aerospace generator drive system demonstrator. The converter is fed by a multiphase high-speed/high-frequency permanent magnet generator. The main aim of the work is to demonstrate for the first time the feasibility of an MW-class generator system meeting future hybrid-electric propulsion requirements. A concept with multiple and isolated three-phase systems feeding different power buses is proposed to meet the availability requirements. Multiple converters (one for each three-phase system) are connected in series and/or in parallel to achieve the rated power and dc-link voltage. This article describes the key design concepts and the development and testing of the converter to meet the challenging application requirements. Reduced power tests are carried out on a full-scale 4 MW converter prototype, validating the proposed design. The work represents a step forward in terms of voltage, power, and output frequency with respect to the state-of-the-art.