Megaspeed Drive Systems: Pushing Beyond 1 Million r/min

The latest research in mesoscale drive systems is targeting rotational speeds toward 1 million r/min for a power range of 1-1 kW. Emerging applications for megaspeed drives (
MegaNdrives
) are to be found in future turbo compressor systems for fuel cells and heat pumps, generators/starters for portable nanoscale gas turbines, printed circuit board drilling and machining spindles, and electric power generation from pressurized gas flow. The selection of the machine type and the challenges involved in designing a machine for megaspeed operation such as the winding concepts, a mechanical rotor design capable of 1 000 000 r/min, the selection of magnetic materials for the stator, and the optimization concerning high-frequency losses and torque density are presented. Furthermore, a review of the advantageous inverter topologies, taking into account the extremely low stator inductance and possible high-speed bearing types such as ball bearings, air bearings, foil bearings, and magnetic bearings, are given. Finally, prototypes and experimental results originating from
MegaNdrive
research at Swiss Federal Institute of Technology Zurich are discussed and extreme temperature operation and power microelectricalmechanical system are identified as targets for future research.