High-speed Synchronous Reluctance Motor Research Articles

Adopting the Topology Optimization in the Design of High-Speed Synchronous Reluctance Motors for Electric Vehicles

This article deals with the design of high-speed synchronous reluctance motors for electric vehicle applications. The need to enhance the power density and to lower the cost leads to research on high-speed motors with a reduced amount of rare earth. Pure synchronous reluctance motors potentially operate at high speed and exhibit a cost-effective rotor compared to permanent magnets and induction motors. Nevertheless, they present reduced performances in deep flux weakening operations, in particular when the so-called radial ribs are introduced to increase the mechanical robustness of the rotor. In this article, the introduction of the radial ribs and the related design challenges are investigated and discussed. The adoption of the topology optimization tool that is able to optimize the amount, the positioning, and the sizing of suitable structural ribs is presented. A design flow integrating the topology optimization is presented. The approach leads to an original positioning of the radial ribs able to preserve the performance of the motor at high operating speed enhancing the mechanical integrity of the rotor.

Synchronous Reluctance Motors With an Axially Laminated Anisotropic Rotor as an Alternative in High-Speed Applications

The performance capabilities of an axially laminated anisotropic rotor (ALA) in a high-speed synchronous reluctance motor (SynRM) were studied. A 12 kW ALASynRM was designed as an alternative to a high-speed induction motor (IM) with a solid rotor. The electromagnetic design was implemented taking into account possible issues related to the new manufacturing methods, which require thicker rotor layers than in a typical ALA. The ALASynRM shows a higher efficiency than the corresponding IM with a smooth or slitted solid rotor equipped with copper end rings. To verify the design method, a prototype IM with a smooth solid rotor was built and tested. In the analysis, it was found that, similar to IMs, in an ALASynRM a considerable part of losses takes place in the rotor despite the absence of slip-related losses in the SynRM. The distribution of eddy current losses in the ALA rotor is significantly uneven. The torque ripple in the ALASynRM is considerably larger than the corresponding ripple in IMs.

Influence of Magnetic and Nonmagnetic Layers in an Axially Laminated Anisotropic Rotor of a High-Speed Synchronous Reluctance Motor Including Manufacturing Aspects

The impact of the thickness of the magnetic and nonmagnetic layers in an axially laminated anisotropic (ALA) rotor in a synchronous reluctance motor (SynRM) aimed at high-speed applications was studied. Considering possible manufacturing issues, the layers are desired to be thick rather than thin. At the same time, the layer thickness is related to the electromagnetic capabilities of the ALASynRM. In the study, a 12 kW ALASynRM was considered. As a reference, a 12 kW IM with a smooth solid rotor with copper end rings was used for comparison with the designed ALASynRM. The manufacturing procedures of an ALA rotor with certain materials were verified in practice. Strength tests of the samples were implemented showing the suitability of the selected materials for application in the prototype. In the electromagnetic design, the thickness of the ALA rotor layers has shown to have a significant impact on the rotor eddy current losses. The stator iron losses and the winding Joule losses also depend on the rotor design. Torque ripple is considerably affected by the thickness of the rotor layers and their position in relation to the stator slots.

HIGH SPEED SYNCHRONOUS RELUCTANCE DRIVES FOR MOTOR SPINDLES

This article presents a new design for setting up high speed synchronous reluctance motors (SynRM) in motor spindle applications for up to 30,000 rpm. The transversal laminated SynRM rotor package is supported by thin steel sheets and a shaft nut to exert a constant axial clamping force. Both, numerical and practical investigations are carried out using FEM-analysis and a test bench for centrifugal force load tests. The objective is to find out at which speed the elastic deformation changes into the plastic deformation. The beginning of plastic deformation is a failure criterion in electric motor construction.