Design of a High-Speed 100,000 rpm 8kW Permanent Magnet Synchronous Machine

The permanent magnet synchronous machines are currently widely used in various applications for their favorable parameters, such as high power density, low mass and volume. Permanent magnet synchronous machines are appropriate for such drives, where precise control is required and they are also brought to use in high-speed applications, which impose special requirements to the electric drives. This paper deals with the design of high-speed permanent magnet synchronous machine, which should achieve the same output performance per motor volume, as an existing machine used for electrically assisted turbocharger. In the first part, the paper describes initial comparison of 4 rotor topologies, which were considered as possible options for the design. Initial electromagnetic analysis of the topologies is provided by means of analytical and finite element method, where the rotors are modelled with one stator arrangement and their output performance is investigated. Mechanical analysis of the rotor topologies is also provided by means of finite element method. In the second part, 2 options of selected rotor topology are compared and the final design of the high-speed permanent magnet synchronous machine is defined. In the third part, the stator arrangement is adapted to selected rotor and it’s geometry is optimized in aim to reach highest output torque and power. Electromagnetic, thermal, and dynamic performance of the final high-speed permanent magnet synchronous machine design is analyzed by simulations.