Methodology to Evaluate the Mechanical Stress in High-Speed Electric Machines With Buried Magnets

High-speed electric machines are gaining importance due to their high power density. The evaluation of the mechanical stress in the rotor is a crucial part of the design process for this type of machines. It is insufficient to evaluate just the static mechanical stress at maximum speed. The dynamic mechanical stress between the state of standstill and maximum speed needs to be considered as well to ensure the high fatigue strength of the rotor. One criterion that is commonly used to analyze the dynamic load in a material is the Smith diagram. In this work, a new methodology is introduced to consider both, the dynamic and the static mechanical stress, in the rotor of a high-speed electric machine. First, the von Mises stress criterion is used to examine the static mechanical stress in the rotor core. Second, the Smith diagram is used to evaluate the dynamic mechanical stress and the high fatigue resistant of the rotor. The methodology is, then, applied to a high-speed electric machine with two different types of buried magnets: 1) a rotor with buried magnets in v-shape and 2) a rotor with a buried bar magnet. Both rotors are analyzed concerning their state of stress. It can be seen that high dynamic stress occurs at the bridges in the rotor. The stress alternates with an amplitude up to σ
_alt
= 290 MPa. The designs are though limited due to the high static stress at the bridges of the magnet slot.