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Machines
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Optimal Design of a High-Speed Motor
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Optimal Design of a High-Speed Motor

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Electrical Machines and Drives".

Deadline for manuscript submissions: closed (31 December 2022) | Viewed by 14222

Special Issue Editors

Prof. Dr. Emil Kurvinen

E-Mail Website
Guest Editor
Machine Design, University of Oulu, 90570 Linnanmaa, Finland
Interests: machine design; computational mechanics; high-speed electrical machines; rotordynamics; mechatronics
Prof. Dr. Jussi Sopanen

E-Mail Website
Guest Editor
Department of Mechanical Engineering, School of Energy Systems, Lappeenranta-Lahti University of Technology LUT, 53850 Lappeenranta, Finland
Interests: dynamics and vibrations; rotordynamics rolling element; bearings machine design; multibody system dynamics

Special Issue Information

Dear Colleagues,

We are pleased to invite you to contribute original research contributions to a Special Issue on the subject of "Optimal Design of a High-Speed Motor".

High-speed electric machines are a specific type of electric machine with a surface velocity of over 100 m/s. In these types of machines, the standard design methods are not effective enough due to the high switching frequencies in electric machines, rotor dynamics (which limit the speed), and bearings, whereby rolling element bearings, journal, or active magnetic bearings are employed. Due to these factors, alternative methods need to be developed. In addition, due to the high rotation speed, the rotors typically integrate the application directly to the end without gears and, therefore, are used in various applications such as compressors, traction applications, propulsion applications.

In addition, it is notable that different sizes of high-speed machines have unique features, e.g., for physically smaller machines, the manufacturing and dynamical aspects are different compared to physically larger machines. This may be due to, e.g., the tolerances and frame, which may have an influence on the rotor dynamics. Different types, sizes, and applications (compressors, traction applications, propulsion applications) of machines have their own unique aspects of importance. The aim of this Special Issue is to gather accounts of research related to the design of high-speed machines.

High-speed machines can achieve very high efficiency, compactness in size, and long lifecycle, thereby offering sustainable solutions for their various applications. However, these machines currently constitute a marginal portion of the EM industry, and one factor which hinders their broader adoption is the complex design process of these types of machines. Medium- and large-power high-speed machines are especially of interest.

This Special Issue thus aims for the advancement of research addressing the machine design of high-speed machines, including all relevant aspects.

In this Special Issue, original research articles and reviews are welcome. Topics of interest for publication include, but are not limited to the following:

  • Multidisciplinary design process
  • Rotor constructions for high-speed machines, e.g., squirrel cage and PM machines
  • Conceptual design of high-speed rotors
  • Semi-automatic iterative design process
  • Control of high-speed machines
  • Multiphysics analysis and optimization of high-speed machines
  • System identification
  • Additive manufacturing in high-speed rotor design
  • Manufacturing and commissioning

We look forward to receiving your contributions.

Prof. Dr. Emil Kurvinen
Prof. Dr. Jussi Sopanen
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Machines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • multiphysics design
  • high-speed machines
  • iterative design
  • rotor dynamics
  • thermal analysis
  • electric machine design
  • control
  • operation
  • system identification

Published Papers (5 papers)

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Research

31 pages, 7596 KiB  
Article
Optimal Design of High-Speed Electric Machines for Electric Vehicles: A Case Study of 100 kW V-Shaped Interior PMSM
by Taha El Hajji, Sami Hlioui, François Louf, Mohamed Gabsi, Guillaume Mermaz-Rollet and M’Hamed Belhadi
Machines 2023, 11(1), 57; https://doi.org/10.3390/machines11010057 - 03 Jan 2023
Cited by 5 | Viewed by 3844
Abstract
The need of compact machines increased in recent years due to increases in raw materials’ price. Hence, many studies are currently being conducted on high-speed challenges to propose an optimal design methodology. AC losses in windings are often not included in the optimization [...] Read more.
The need of compact machines increased in recent years due to increases in raw materials’ price. Hence, many studies are currently being conducted on high-speed challenges to propose an optimal design methodology. AC losses in windings are often not included in the optimization process and are treated in post-processing by choosing a suitable conductor’s diameter to mitigate skin and proximity effects. This paper presents an optimization and design methodology for high-speed electric machines considering these losses, using models with an interesting trade-off between computation time and accuracy, which is helpful for large-scale optimization, in which more than 9,600,000 machines are evaluated. Optimizations are conducted on 100 kW high-speed one-layer V-shaped interior permanent magnet synchronous machines, widely used in vehicles thanks to their high power density, based on the specifications of the Peugeot e208, for different values of pole pairs and maximum speed. The influence of lamination thickness, fill factor, and maximum current density on the optimal design is also investigated. This paper concludes the utility of increasing speed to achieve high power density and proposes best alternatives regarding automotive constraints. Results show that the number of pole pairs is not always a key parameter in obtaining the lowest volume, especially at high speed. Full article
(This article belongs to the Special Issue Optimal Design of a High-Speed Motor)
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13 pages, 5776 KiB  
Article
Analysis of Load Loss Characteristics of FeCo Alloy High Speed Permanent Magnet Motor
by Dajun Tao, Guifen Li, Peng Hou and Gang Hu
Machines 2022, 10(9), 735; https://doi.org/10.3390/machines10090735 - 26 Aug 2022
Viewed by 1218
Abstract
In order to study the change law of loss and efficiency of high-speed permanent magnet motor (HSPMM) under load after using FeCo_B800 alloy material instead of silicon steel sheet DW310_35 material to make iron core, two FeCo_B800 stator materials with the same structure [...] Read more.
In order to study the change law of loss and efficiency of high-speed permanent magnet motor (HSPMM) under load after using FeCo_B800 alloy material instead of silicon steel sheet DW310_35 material to make iron core, two FeCo_B800 stator materials with the same structure and size parameters were developed. HSPMM and HSPMM of silicon steel DW310_35 stator material. The loss and efficiency characteristics of the two motors under the same operating conditions were tested by the experimental method, and the losses of the two motors at different load rates were compared and analyzed by means of the finite element method. The research results show that at light load, the FeCo_B800 motor stator core loss is lower than the DW310_35 silicon steel sheet motor, and the efficiency advantage is very obvious; however, with the increase of the load rate, the FeCo_B800 motor stator core is seriously saturated, resulting in the distortion of the winding magnetomotive force waveform. The loss caused by the harmonics of the winding magnetomotive force is higher than that of the DW310_35 silicon steel sheet motor, and the efficiency advantage of the FeCo-B800 motor gradually decreases with the increase of the load rate. Full article
(This article belongs to the Special Issue Optimal Design of a High-Speed Motor)
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19 pages, 12184 KiB  
Article
Comprehensive Analysis of Influencing Factors of AC Copper Loss for High-Speed Permanent Magnet Machine with Round Copper Wire Windings
by Guanghui Du, Weilin Ye, Yufeng Zhang, Lu Wang and Tao Pu
Machines 2022, 10(9), 731; https://doi.org/10.3390/machines10090731 - 26 Aug 2022
Cited by 2 | Viewed by 2252
Abstract
AC copper loss from stator winding is one of the main losses of the high-speed permanent magnet machines (HSPMMs) and directly affects the performance of the machines. AC copper losses are influenced by many factors, including the frequency, conductor diameter, temperature performance, etc. [...] Read more.
AC copper loss from stator winding is one of the main losses of the high-speed permanent magnet machines (HSPMMs) and directly affects the performance of the machines. AC copper losses are influenced by many factors, including the frequency, conductor diameter, temperature performance, etc. These factors cause the AC losses to increase significantly at high frequencies due to the skin effect and proximity effect. In this paper, a comprehensive analysis of the AC copper losses of HSPMMs with round copper wire windings is presented. Firstly, the structure and parameters of a 60 kW, 30,000 rpm high-speed permanent magnet machine are provided. Then, based on this parameter, a 2D-finite element model (2D-FEM) is established to obtain the AC copper loss. Through the eddy-current field analysis, the current density distribution of the stator winding and the variation trends of AC copper losses under different frequencies are observed. In addition, by comparing the winding current density distribution and the AC copper loss value under different conditions, the influencing factors of AC winding losses are comprehensively analyzed, including the frequency, conductor diameter, number of conductors per slot, notch height of the stator slot, and working temperature. Finally, four stator coil cases are manufactured, which have different conductor diameters and wire strands. The AC losses of the four cases at different frequencies are tested, and the theoretical results are verified by measuring the AC/DC loss ratios (kac) of different conductor cases at various frequencies. Full article
(This article belongs to the Special Issue Optimal Design of a High-Speed Motor)
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19 pages, 11392 KiB  
Article
Rotor Strength Analysis of FeCo-Based Permanent Magnet High Speed Motor
by Peng Hou, Baojun Ge, Dajun Tao, Bo Pan and Yue Wang
Machines 2022, 10(6), 462; https://doi.org/10.3390/machines10060462 - 09 Jun 2022
Cited by 8 | Viewed by 2188
Abstract
To solve the problem of tension stress caused by centrifugal force and caused by high-speed operation of permanent magnet (PM) rotor, a FeCo-based PM rotor structure model is proposed. Based on the thick-walled cylinder theory, the uniform analytical calculation formulas of strain field, [...] Read more.
To solve the problem of tension stress caused by centrifugal force and caused by high-speed operation of permanent magnet (PM) rotor, a FeCo-based PM rotor structure model is proposed. Based on the thick-walled cylinder theory, the uniform analytical calculation formulas of strain field, displacement field, and stress field of high-speed permanent magnet rotor are derived, and the stresses of FeCo-based PM and sleeve are obtained. The correctness of analytical calculation method (ACM) is verified by finite element method (FEM). Based on the derived analytical formula, the influence of static interference, sleeve thickness, rotating shaft, and PM thermal expansion coefficient on the strength of high-speed permanent magnet rotor is analyzed, and the mechanical design law of high-speed permanent magnet rotor is summarized. Alloy sleeves are usually fitted outside the high-speed permanent magnet rotor to protect the PM from damage. In order to ensure safe operation of PM rotor under hot rotating conditions, strength calculation and check of sleeve and PM must be carried out. Based on the characteristics of slender structure of high-speed rotor, a high-speed permanent magnet motor (HSPMM) with a rated power of 100 kW and a rated speed of 18,000 r/min was produced, and a continuous operation test was carried out to verify the validity of the above theoretical analysis. Full article
(This article belongs to the Special Issue Optimal Design of a High-Speed Motor)
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16 pages, 2775 KiB  
Article
Research on Thermal Error Modeling of Motorized Spindle Based on BP Neural Network Optimized by Beetle Antennae Search Algorithm
by Zhaolong Li, Bo Zhu, Ye Dai, Wenming Zhu, Qinghai Wang and Baodong Wang
Machines 2021, 9(11), 286; https://doi.org/10.3390/machines9110286 - 12 Nov 2021
Cited by 20 | Viewed by 2132
Abstract
High-speed motorized spindle heating will produce thermal error, which is an important factor affecting the machining accuracy of machine tools. The thermal error model of high-speed motorized spindles can compensate for thermal error and improve machining accuracy effectively. In order to confirm the [...] Read more.
High-speed motorized spindle heating will produce thermal error, which is an important factor affecting the machining accuracy of machine tools. The thermal error model of high-speed motorized spindles can compensate for thermal error and improve machining accuracy effectively. In order to confirm the high precision thermal error model, Beetle antennae search algorithm (BAS) is proposed to optimize the thermal error prediction model of motorized spindle based on BP neural network. Through the thermal characteristic experiment, the A02 motorized spindle is used as the research object to obtain the temperature and axial thermal drift data of the motorized spindle at different speeds. Using fuzzy clustering and grey relational analysis to screen temperature-sensitive points. Beetle antennae search algorithm (BAS) is used to optimize the weights and thresholds of the BP neural network. Finally, the BAS-BP thermal error prediction model is established. Compared with BP and GA-BP models, the results show that BAS-BP has higher prediction accuracy than BP and GA-BP models at different speeds. Therefore, the BAS-BP model is suitable for prediction and compensation of spindle thermal error. Full article
(This article belongs to the Special Issue Optimal Design of a High-Speed Motor)
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