SGdrive: Closing the project – A success story

In January 2024, the Department of Electrical Engineering of the University of Malta, started work on the project SGdrive, funded by Xjenza Malta. The project’s full title is High Reliability and High Power Density Starter/Generator System for MEA (SGdrive) and is headed by Prof. Inġ. Michael Galea. The project aimed to address technical challenges in designing starter-generator systems for More Electric Aircraft (MEA). Key technical achievements include lightweight design, high-efficiency thermal management, modular high-fault-tolerant systems, and high-reliability operation control strategies. The University of Malta's focus lies in novel lifetime modelling and prediction techniques, contributing to advancements in aviation electrification technologies.

As the SGdrive project comes to an end in March 2026, it leaves behind more than a set of completed task. It delivers a validated shift in how electrical machines can be designed for reliability from the outset. Moving beyond the traditional approach, where lifetime is assessed only after prototyping, SGdrive successfully demonstrated that reliability considerations can be embedded directly into the design phase through advanced physics-of-failure methodologies. This enables engineers to predict performance degradation and optimise lifetime early, particularly for critical components such as the insulation system.

A key strength of the project lies in its tangible outputs. The proposed methodologies were not only developed but fully validated through experimental testing on a purposely built 45 kW starter-generator prototype. The strong agreement between simulated and measured thermal behaviour provided clear evidence of the accuracy and robustness of the lifetime prediction models. In parallel, the project contributed to the scientific community through three peer-reviewed publications, disseminating its findings and reinforcing its academic impact.

Beyond these measurable outcomes, SGdrive also delivered significant knowledge gains. Insights into reliability-oriented design, thermal management, and system-level modelling have proven transferable across sectors, supporting innovation not only in aerospace but also in areas such as automotive electrification. In this sense, the project’s legacy extends beyond its immediate results. It equips researchers and engineers with tools, methodologies and understanding that will continue to shape future high-performance electrical machine design.

For more information, please contact the principal investigator Prof. Inġ M. Galea or the Department of Electrical Engineering.