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For simple, but realistic rotor configurations with rotational pω,m = rm ⋅ ρ m ⋅ ωoverspeed ⋅ hm (6)
symmetry, the bandage design can be done using the
following formulas [2]. For more detailed investigations in 2
pω,b = rb ⋅ ρ b ⋅ ω overspeed ⋅ hb (7)
case of rotors with an inter-pole gap or with influence of
magnet edges pressing against the bandage, more elaborate
analytical or FE (Finite Element) calculations are necessary.
III. EXAMPLE OF A HIGH-SPEED MOTOR WITH 40 kW AT
Using YOUNG’s modulus E, the sleeve undersize ∆D and the
40000 RPM
bandage height hb, the prestress and the contact pressure due
to shrinking or pressing of the sleeve onto the rotor is given by For a magnetically levitated PMSM with PN = 40 kW, rated
(3) and (4a), if the bandage is considered as a “thin” shell. If speed nN = 40000 rpm, two different rotors with surface
the bandage is considered as a “thick” shell, equation (4b) mounted Sm2Co17 magnets have been designed and built. The
needs to be employed [3]. rotor circumferential speed at overspeed n = 1.2 ⋅ nN =
48000 rpm is vu = 222 m/s. The main parameters of the two
∆D rotors are shown in Table II.
σ t,prestress = ε ⋅ E = ⋅E (3)
da A. Design of rotor M1
To limit the magnitude of air gap flux density harmonics,
σ t,prestress ⋅ hb rotor M1 (Fig. 3) is built with a pole coverage ratio of
pc,prestess = (“thin shell”) (4a) αe = 87 %. To avoid eddy currents, the inter pole gap of rotor
rb
M1 is filled with a non-conducting resin mass with a low mass
Rotor M1 M2
rotor outer diameter da 88.6 mm 83.6 mm
pole coverage ratio αe 0.87 1.00
air gap δ 0.7 mm 3.2 mm
thickness of bandage hb 5.7 mm 4.8 mm
magnet height hm 7.0 mm 4.5 mm
bandage undersize ∆D 0.24 mm 0.13 mm
mounting of bandage axial cold
pressing shrinking
at –190°C
bandage stress limit σt,max 1100 N/mm² 1100 N/mm²
Figure 4. Calculated radial stress variation σ r inside the bandage of rotor M1
at n = 40000 rpm and ϑ = 150°C
N/mm2
1200
To improve the mechanical strength, the second rotor M2 IV. MECHANICAL DESIGN OF BURIED MAGNET HIGH-
SPEED MACHINES
experienced some major design changes compared to rotor M1
(Table II). First of all, the inter-pole gap has been avoided
(α e = 100%), as shown in Fig. 8. That means, that the magnets
are evenly distributed along the circumference, thus achieving
rotational symmetry without any edge effect. In this case,
equations (1)...(6) lead to satisfying results, which can be
verified by a FE calculation (Fig. 9). Furthermore, the air gap
has been increased from δM1 = 0.7 mm to δM2 = 3.2 mm in
order to reduce the air friction losses inside the air gap and
hence reduce rotor heating. The magnet height has been Figure 10. PMSM with buried magnets.
reduced from hm,M1 = 7 mm to hm,M2 = 4.5 mm, which is still
providing a sufficient demagnetisation reserve, but reduces the If the permanent magnets are “buried” within the rotor iron,
centrifugal forces acting on the magnets. Due to lower flux the rotor iron itself fixes the magnets (Fig. 10). No carbon or
density an increased current loading is necessary to keep the glass fibre bandage is needed, thus reducing the total air gap
output power unchanged. Reducing the bandage sleeve and the required amount of magnet material. Exact analytical
undersize from ∆DM1 = 0.24 mm to ∆DM2 = 0.13 mm also calculation of the mechanical stress inside the iron sheet is
allowed for a more gentle procedure to mount the bandage difficult, therefore, FE-calculations are recommended [5].
onto the rotor structure. The rotor has been cooled with liquid However, for simple magnet arrangements with buried
nitrogen LN2 to a temperature of –190°C. Due to rotor magnets as shown in Fig. 10, analytical approaches using an
shrinking, the bandage could be mounted onto the rotor equivalent ring arrangement can still give a good estimate
without any axial pressure. Rotor expansion during thermal about the mechanical stress. The magnets are inserted into the
adaptation to room temperature caused the stretching of the slots, so no prestress is given. The outer iron bridge must
bandage and thus the generation of prestress. The carbon fibre withstand its own centrifugal forces and that of the magnets.
material is very strong in terms of tangential stress while being Thermal expansion of iron and magnets is similar, so the
very sensitive to bending forces. As glass fibre composite is temperature influence on stress is small. An analytical
less sensitive to bending stress, a thin layer of glass fibre approach to calculate the mechanical stress on the rotor
bandage has been introduced to the inner layer of the bandage structure is shown in Fig. 11. The centrifugal forces acting on
to withstand bending effects due to segmented magnets. Fig. 9 the magnets and the covering iron bridge are
shows the results of the calculations using (1) ... (7).
Amagnet + AFe,o
ρ equiv = ρ Fe ⋅ . (8)
Aequiv
Both the masses of the magnet and the iron that covers the
magnet are transformed into the equivalent ring. Thereby it is
assured, that the equivalent ring suffers from the same
centrifugal forces as the original arrangement. With the outer
and inner radii of the equivalent ring requiv,o and requiv,i, the Figure 13. Equivalent rotor design to M2 using buried magnets. No-load field
plot with neglected stator slotting.
tangential stress inside the equivalent ring under rotation at
overspeed can be determined as So, the maximum permissible stress inside the rotor iron is
2
requiv,o + requiv,i σ t,max = 2 ⋅ σ equiv < Rp0.2 (11)
σ t,equiv = ⋅ ω overspeed
2
⋅ ρ equiv . (9)
2 A. Example for the calculation of the mechanical strength of
a buried magnet rotor
So far the calculation does not pay attention to local peak To compare the mechanical behaviour of surface mounted
stress caused be the uneven distribution of the magnets and the and buried magnet PMSM, an alternative design to the
shape of the magnet edges. By designing round shaped slot previously discussed surface mounted magnet PMSM (rotor
edges, the increase of stress at these edges caused by the notch M2) is considered (Fig. 13). In order to obtain a comparable
effect can be limited to about 100% (factor 2). Therefore, the design M3, rotor diameter, mechanical air gap and the
maximum mechanical stress is located at the slot edges: fundamental of the air gap flux density are kept unchanged.
The non-linear magnetic circuit including iron saturation has
σ t,max = 2 ⋅ σ t,equiv (10) been designed using Finite Element calculations. The
dimensions of design M3 are listed in Table III. The thickness
The stress-strain characteristic σ(ε) of iron is non-linear as of the iron bridge at the narrowest location is 1.66 mm.
shown in Fig. 12. The maximum tensile stress inside the iron According to the explanations above, this is also the value
must stay below the iron sheet yield strength Rp0.2. A typical chosen for the height of the equivalent ring hequiv. With the
value for Rp0.2, e.g. for M270-35A sheets, is dimensions given in Table III, the cross sectional area of one
Rp0.2 = 450 N/mm2. That means that putting a stress of Rp0.2 to magnet and its covering iron amounts to
the material will lead to a permanent (irreversible) relative
deformation of 0.2 %. This is accepted as permanent Amagnet + AFe,o = 184.5 mm 2 (12)
deformation of the iron sheets and therefore defines the limit
of the stress which can be applied to the material. With special
while the cross sectional area of the equivalent ring section is
high strength materials yield strength can reach values of up to
Rp0,2 = 850 N/mm2 [7]. 2 2 2
Aequiv = π (requiv ,o − requiv ,i ) / 8 = 53.4 mm . (13)
Rotor M3
rotor outer diameter da 83.6 mm
air gap δ 3.2 mm
magnet height hm 3.6 mm
magnet width bm 25 mm
minimum height of iron bridge 1.66 mm
iron yield strength 450 N/mm2
Amagnet + AFe,o kg
ρ equiv = ρ Fe = 3.45 ⋅ ρ Fe = 26.9 ⋅ 10 3 . (14)
Aequiv m2