Design Methodology for Series of IE4/IE5 Synchronous Reluctance Motors Based on Radial Scaling

The paper describes a methodology for design of high efficiency synchronous reluctance motor series in frame sizes IEC-80 up to IEC-160. The series of motors assumes a set of motors designed for a range of power ratings at few typical rated speeds but for the same rated voltage and type of cooling. The methodology is based on optimal rotor design for a certain frame size and its scaling to obtain other motor designs in the series. For the motors in the same frame size as the referent optimal design, the other motors are designed using the optimal lamination with the adjustment of axial stack length and number of turns per coil. For the motors in smaller frame sizes, the rotor lamination is obtained using a novel idea: proportional radial down-scaling of the original optimal lamination design along with the adjustment of stack length and number of turns. The method allows significant reduction of total optimization time. Only two optimization runs are needed to get the dimensions and performance data for the complete motor series which involves 30 motors in 6 different frame sizes.