HPDM-320: A High Power Density 320 kW Direct-Drive Generator with Integrated Power Electronics
AFWERX · AFWERX TACFI · AFWERX
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Description
The TACFI contract consists of 11 tasks over a 24-month period of performance for the baseline funding of $1,900,000 USD. The Work Plan consists of the development of the HPDM-320, integration into the Verdego VH3 hybrid powerplant, and system-level ground testing against mission profiles provided by DAF. The HPDM-320 is a variant of the HPDM-250 and builds off the core technology tested in our Phase II effort and thus will have a very streamlined development process. This multisector integrated motor drive is extremely power dense and has a continuous output power of 320 kW (430 HP) in a lightweight package that weighs 35 kg (77 lbs), putting its power density at 9.1 kW/kg. This unit requires very low maintenance and has a max shaft speed of 2500 RPM so no gearbox is required for driving a propeller or direct coupling to an engine for power generation. The project will commence with a kickoff meeting with H3X, Verdego, and the DAF customer, aligning all parties on the project's objectives, followed by the critical task of Requirements Definition, establishing a clear roadmap for the system’s design and performance criteria. H3X will then develop a detailed design using the core technology building blocks tested on the HPDM-250 platform during the Phase II in order to meet the requirements defined. In conjunction, advanced software tools will be used to simulate the system's electromagnetics, electrical circuits, thermal, structural, and rotor dynamics under various conditions ensuring the design meets the defined requirements. A hardware prototype will then be built and comprehensive functional testing will be performed at various steps in the build process to collect crucial data on each component's performance, informing further refinements before full-scale assembly and testing. After the unit goes through functional testing and checkout, it will then be installed on a dynamometer at H3X, and will be tested up to its maximum power. This crucial stage paves the way for the seamless delivery and integration of the first HPDM-320 prototype into Verdego's VH3 platform, accompanied by dedicated support from H3X to guarantee successful system adaptation. The project's final phases focus on system-level testing within the VH3 platform, confirming the HPDM-320's capability against mission performance and reliability requirements. The contract concludes with a Test Summary Report, detailing key findings, performance data, & conclusive analyses, affirming the system’s operational excellence and readiness for deployment in transformative aerial mobility solutions.