4.1. Objective Function for the DC HTS Cable
An optimization procedure is conducted to optimally design the structure and fault performance of a DC HTS cable based on the following fitness function, shown in Equations (18)–(24):
where
is the former weight,
is the superconducting layer weight,
is the former volume,
is the former density,
is the cable length,
is the outer radius of the former,
is the inner radius of the former,
is the number of HTS tapes,
is the density of each layer of HTS tape,
is the volume of each sub-layer of HTS tape,
is the number of considered sub-layers,
is the width of HTS tapes,
is the thickness of tape sub-layers,
is the peak temperature of YBCO tapes,
is the current passing through each tape, and
is the temperature-dependent critical current of the HTS tape. To solve this multi-objective function, the parameters of the NSGA II algorithm are considered as tabulated in
Table 1.
4.2. Cable and Test System Specifications
Three HTS cables were considered in this study, known as cable A, cable B, and cable C. The first cable is designed to carry 560 A current and 2.25 MW power in the drivetrain of electric aircraft. Then, to increase the power density of the cable, its current was increased to 2 kA while using the same HTS tape of cable A. Due to the low critical current of YBCO HTS tapes in cable B, three layers are needed to carry 2 kA/9 MW, which results in a weight increase in the cable and power density reduction. To solve this issue, the HTS tape was changed to another type of YBCO tape that has a higher critical current at 65 K.
Table 2 shows the properties of the three DC HTS cables discussed and analyzed in this paper. For these cables, the critical temperature is considered to be 92 K, the heat transfer coefficient (
) is considered to be 2000
, and the fluid bulk temperature (K) is considered as 65 K.
Table 3 lists the specifications of the two different YBCO tapes used in DC cable analysis according to [
23,
24]. Former material must have a low resistivity, low density, high cryogenic stability, and high specific heat capacity. Based on these requirements, four different candidates were chosen also for our study and are shown in
Table 4 based on their different properties.
To analyze the behavior of understudied DC HTS cables, the test grid shown in
Figure 4 was put to work. This figure represents the characteristics of fault current in the DC grid of a cryo-electric aircraft. The current waveform injected into the DC HTS cable by this grid is shown in
Figure 5. As can be seen, after 10 ms, the current increases to charge the capacitor C
f and when it is discharged, the current gets back to its operational state.
4.3. Multi-Objective Optimization Results
Figure 6a shows the Pareto front related to cable A with a 0.56 kA nominal current. According to this figure, the weight range of DC cable with copper former is from 110 kg to around 300 kg, the same as brass and stainless steel formers, which is due to the fact that they have a density value very similar to each other. On the other hand, DC cable with aluminum former has a range of 60 kg to 150 kg, which is a result of the low density of aluminum, around 2700 kg/m
3. Thus, for cable A, aluminum is selected as the lightest former while copper has a better performance when one considers the peak temperature of the superconducting layer as the objective function. Also, if we consider the third objective function, it can be seen that F
3 has values ranging from 0.2 to 0.5 that lie in an acceptable range.
Figure 6b illustrates the Pareto front of multi-objective optimization for cable B. This cable consists of three superconducting layers, two dielectric layers, and one former layer. In order to have a sufficient number of SC
1 tapes in one HTS layer for carrying 2000 A rated current, the former must have a radius of around 40 mm, which makes just the weight of the former around 220 kg. The weight of HTS tapes and dielectrics must be added to this value, which results in an extremely heavy HTS cable that could not fit into an electric aircraft. Thus, by adding the new layers to cable B, its weight range has increased in comparison to cable A, while the delivered power by cable B has also increased by 300%. The important factor here is the value of the third objective function that in some cases increased to 0.9, which could jeopardize the safe operation of DC HTS cable and cause hot spots and quench. Finally,
Figure 6c shows the results of optimization on cable C, which has a 2000 A current, one superconducting layer, one dielectric layer, and one former. The number of superconducting and dielectric layers has been reduced by changing the superconducting tape to SC
2. It should be noted that the presented values of weight are related to the summation of the weight of former, HTS tapes, and dielectrics.
4.4. Thermoelectric Characteristic of Optimized Cable
In this section, after selecting the optimum structure for the understudied DC HTS cables among the results offered by the Pareto front, the electrothermal characteristic of DC HTS cable is evaluated. For this purpose,
Table 5 tabulates the selected design for DC HTS cable A with different former materials. It can be seen that the lightest cable is the one with aluminum former, which has 49% lower weight than one with copper former, 44% lower than one with stainless steel former, and 48% lower than cable with brass former. Meanwhile, cable with copper former has a temperature of 14%, 52%, and 54% lower than cable with aluminum, stainless steel, and brass formers, respectively. This shows that copper has the best thermal performance among all former materials, which is due to its lower resistivity, which generates a lower heat load, and also the acceptable heat capacity of copper. So, for further analyses, the cable with copper former is selected as the cable with the best performance against faults while the cable with aluminum former is selected as the lightest DC HTS cable A.
Table 5 shares the information on the structure of the selected former for DC cable B resulting from NSGA II optimization. Although the former radius and thickness remained approximately similar to cable A, the weight of the optimized structure has been increased. This increase resulted from adding extra superconducting and dielectric layers to the cable. So, in the optimized structure of cable B, the weight of the cable with copper former has increased by 38% while its temperature has only been reduced by 4%. These changes are also valid for other former materials in cable B, compared to cable A. Finally, by changing the type of superconducting tape into one with a higher critical current, i.e., SC
2, both the weight and size of DC cable, i.e., Cable C, have been reduced, as shown in
Table 5.
Now the thermal characteristic of all three cables must be evaluated to show how HTS cables would perform against a fault in the drivetrain of electric aircraft. This is conducted by considering two optimum scenarios, one with the lowest weight and the other with the lowest temperature during faults.
Figure 7 depicts the temperature characteristic of HTS tapes in each of the understudied cables. Due to the lower critical current of HTS tapes in cable A, the peak temperature in this cable is higher than in the other two cables, with both copper and aluminum formers.
The temperature of copper and aluminum formers are shown in
Figure 8 for all three cables. Due to the higher thermal mass of former layers, the temperature in this layer increases at a slower rate in comparison to HTS tapes. As seen in
Figure 8, the peak temperature of former in cable C is lower than the peak temperature of formers in cables A and B. This is due to the fact that in cable C, the critical current is higher than the critical current in the other two cables. As a result of this, HTS tapes transit to a normal state at a later time (which can be considered as a kind of a slower transition) and thus, less fault current passes through the former of cable C. Consequently, the Joule loss generated in the former layer of cable C is lower than Joule losses in cables A and B, and this results in lower peak temperature of the former in cable C.
Finally, the temperature profile of dielectric layers is shown in
Figure 9a,b for copper and aluminum former cables, respectively. The different temperature profile in dielectric layers of the second DC HTS cable is a result of a lower heat accumulation ratio in these layers, compared to cable A and cable C.
By knowing these temperature profiles, one can evaluate the temperature characteristic of different layers in HTS cables during the flight missions of a cryo-electric aircraft. Another important point is that the temperature profile of aluminum-based former HTS cables is not so different from copper-based former cables. This means that with a 50% weight reduction in DC HTS cable, the temperature of HTS tapes increases by just 16%. This means that the peak temperature of HTS tapes is still way lower than 300 K, known as the conservative temperature limit for YBCO tapes [
25].
To calculate the specific mass and power density of the DC HTS cable, in addition to the weight of former, HTS tapes, and PPLP-based dielectrics, there is a need for adding the weight of cryostat and coolant fluid to the total weight of the cable. For weight calculation of the dielectrics, according to [
26], a 2.5 mm thickness would be sufficient for power cables in a voltage range of 4–6 kV while the PPLP dielectric has a density of 1098 kg/m
3 [
27]. After that, a cryostat made out of stainless steel with a thickness of 1 mm and outer radius of 37 mm, for cables A and C, and 43 mm for cable B was considered. The difference between the cryostat inner radius and outer radius of the last layer of cable defines the total volume of coolant fluid, LN
2, with 811 kg/m
3 density [
27]. This illustration is shown in
Figure 10. By doing this, the total weight of DC HTS cables with respect to different former materials is calculated and tabulated in
Table 6. After that, and by dividing the cable weight to the length of the cable (100 m), the specific mass could calculated. Then, the power of each cable in kW is divided to the weight of the cable to calculate the power density of cable. Based on [
28], the specific mass for a HTS cable to be fitted into a cryo-electric aircraft system must be lower than 5 kg/m, which is the case for all types of understudied cables except cable B that has specific mass of 7.3 kg/m and 6.7 kg/m for copper and aluminum formers, respectively. On the other hand, the highest power density belongs to cable C with aluminum former, which is 12% higher than cable C with copper former. By comparing the cables with aluminum former, cable C has approximately 35% and around 310% higher power density in comparison to cable B and cable A, respectively. Moreover, cable B with aluminum former has 205% higher power density compared to cable A. In other words, HTS cables would have more benefits if they were used for high current, low voltage (lower deictic weight), and high-power applications, as can be observed in
Table 6.