Multidisciplinary Design Process of a 6-Slot 2-Pole High-Speed Permanent-Magnet Synchronous Machine

Abstract

High-speed permanent-magnet synchronous machines (HS PMSMs) are a popular topology among modern electrical machines. Suitable applications for such machines are low-power vacuum pumps, compressors, and chillers. This paper describes a systematic design methodology for an HS PMSM using two case studies. The design process for such high-speed (HS) machines is multidisciplinary and highly iterative due to the complex interaction of the many design variables involved. Consequently, no single optimum solution exists, and multiple possible solutions can meet the customer requirements. Practical solutions should be within acceptable thermal limits, should be energy-efficient, and should be rigid enough to withstand the forces exerted during operation. The proposed design flow is divided into steps that are presented in this paper in the form of a flowchart with emphasis on mechanical aspects. Each step represents a task for a thermal, mechanical, or electrical engineer. The features of each step and the prerequisites for moving to the next step are discussed. The described methodology was implemented in the design of two HS PMSMs. The output performance results of the design flow are compared with measured results of the prototypes. The design process described in this paper provides a straightforward procedure for the multidisciplinary design of HS permanent magnet electrical machines.