Abstract

High speed machines are gaining popularity in more and more applications. Besides permanent magnet (PM) machines, switched reluctance machines (SRMs) are very competitive candidates for high-speed applications in high-temperature environments due to their single material rotor without PMs. However, the conventional rotor geometries of SRMs are not suitable for the ultra-high speed applications. In this article, a novel high-strength, high-torque-density, high-efficiency rotor design for the ultra-high speed SRMs is proposed. First, a three-dimensional finite-element analysis is conducted to calculate the von-Mises stress distribution of the proposed rotor and shaft. Then, in order to improve the bonding and robustness of the design, proper high-strength adhesives are used and modeled based on the cohesive zone model. A parametric study is conducted to find the optimal length of the rotor stack. A thermal stress case study is also conducted. Finally, several prototypes are built to validate the manufacturing feasibility of the proposed design.

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