Static and cyclic mechanical loads inside the rotor lamination of high-speed PMSM

Karthaus, Jan; Hameyer, Kay

doi:10.1109/edpc.2017.8328152

Cited by 9 publications

(7 citation statements)

References 15 publications

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“…But, validation by measurements is missing [1,[12][13][14][15]. Karthaus performs a comparison for a Permanent Magnet Synchronous Machine (PMSM) with interior magnets, where he compares the calculated deformation at the rotor surface with a measurement, using laser-based distance sensors [16]. The mechanical stress can then be deduced from the measured deformations using a FEM simulation model.…”

Section: Fig 1 High Speed Pmsm With Bandage and High Speed Im Rotormentioning

confidence: 99%

“…The expansion of the rotor is determined using a spin test, that measures the deformation of the rotor surface for different rotational speeds. The measurement is similar to the setup used in [16].…”

Section: Measurement Setupmentioning

confidence: 99%

“…The deviation between the measurement results and the simulation model might occur due to the modelling of the glue between the magnet and the rotor lamination. In [16], the influence of the glue is analysed for a PMSM with buried magnets and a strong impact on the deformation can be noticed. If the model used here for the surface-mounted PMSM is simulated without the glue and a frictional or bonded contact between the rotor lamination and the magnet is used, the deformations are significantly smaller.…”

Section: Pmsm Rotormentioning

confidence: 99%

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Mechanical stress and deformation in the rotors of a high-speed PMSM and IM

Gerlach

Zajonc

Ponick

2021

Elektrotech. Inftech.

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High-speed electric machines are gaining importance in the field of traction drives and aviation due to their high power density. The evaluation of the mechanical stress in the rotor is one crucial part in the design process for this type of machines. The mechanical stress cannot be measured directly. Accordingly, a validation of the calculated mechanical stress is difficult and normally not performed. Instead of the mechanical stress, the deformation at the rotor surface can be measured using a spin test machine with distance sensors. The deformation can then be used to validate the calculation results.In this paper, the mechanical load exerted on an IM rotor for a $60\,\text{kW}/20000\,\frac{1}{\text{min}}$ 60 kW / 20000 1 min high-speed electric machine and an PMSM rotor for a $75~\text{kW}/25000\,\frac{1}{\text{min}}$ 75 kW / 25000 1 min high-speed electric machine is analysed in detail. The mechanical stress and the deformation are calculated and analysed using a FEM simulation model. Then, a spin test is performed on the two rotors. First, the burst speed is determined by operating two rotor samples above their defined test speed. Then, the deformation is measured at the rotor surface for different operating speeds and the defined test speed. The measurement and the simulation results are compared and discussed.It can be shown that the two designs do not exceed the maximum mechanical stress for the defined operating range. In the deformation measurement of the IM rotor, a plastic deformation up to $\varepsilon _{\text{IM, pl}} = 8$ ε IM, pl = 8 μm and elastic deformation up to $\varepsilon _{\text{IM, el}}=22$ ε IM, el = 22 μm can be seen. In regards to plastics, PMSM rotor expands up to $\varepsilon _{\text{PMSM, pl}}= 5$ ε PMSM, pl = 5 μm. The maximum elastic deformation of the PMSM rotor is $\varepsilon _{\text{PMSM, el}}=40$ ε PMSM, el = 40 μm. The comparison of the calculated and the measured elastic deformation shows good accordance for the two rotor types. Both models are capable of describing the deformation and the state of stress in the rotors. In burst tests, both rotors withstand rotational speeds far above the defined test speed.

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Section: Fig 1 High Speed Pmsm With Bandage and High Speed Im Rotormentioning

confidence: 99%

Section: Measurement Setupmentioning

confidence: 99%

Section: Pmsm Rotormentioning

confidence: 99%

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Mechanical stress and deformation in the rotors of a high-speed PMSM and IM

Gerlach

Zajonc

Ponick

2021

Elektrotech. Inftech.

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“…In the mechanical simulation, not only production but also operating influences on mechanical stresses can be considered. The most significant mechanical load caused by machine operation in the high-speed application is the centrifugal load [40]. In the mechanical simulation tool, the local deformation and the principal stresses are calculated for the rotor and extracted in dependency of the location.…”

Section: Mechanical Simulationmentioning

confidence: 99%

Complete and accurate modular numerical computation scheme for multi‐coupled electric drive systems

Nell

Leuning

Mönninghoff

et al. 2020

IET Science, Measurement & Technology

Self Cite

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“…shrinking) (Fujisaki et al , 2007) or because of operation (e.g. centrifugal forces inside rotors) (Karthaus and Hameyer, 2017). The resulting mechanical stress distribution is given by the mechanical stress tensor which has six different components describing the mechanical stress state in one location.…”

Section: Introductionmentioning

confidence: 99%

Continuous local material model for the mechanical stress-dependency of magnetic properties in non-oriented electrical steel

Karthaus

Elfgen

Hameyer

2019

COMPEL

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Purpose Magnetic properties of electrical steel are affected by mechanical stress. In electrical machines, influences because of manufacturing and assembling and because of operation cause a mechanical stress distribution inside the steel lamination. The purpose of this study is to analyse the local mechanical stress distribution and its consequences for the magnetic properties which must be considered when designing electrical machines. Design/methodology/approach In this paper, an approach for modelling stress-dependent magnetic material properties such as magnetic flux density using a continuous local material model is presented. Findings The presented model shows a good approximation to measurement results for mechanical tensile stress up to 100 MPa for the studied material. Originality/value The presented model allows a simple determination of model parameters by using stress-dependent magnetic material measurements. The model can also be used to determine a scalar mechanical stress distribution by using a known magnetic flux density distribution.

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Static and cyclic mechanical loads inside the rotor lamination of high-speed PMSM

Cited by 9 publications

References 15 publications

Mechanical stress and deformation in the rotors of a high-speed PMSM and IM

Mechanical stress and deformation in the rotors of a high-speed PMSM and IM

Complete and accurate modular numerical computation scheme for multi‐coupled electric drive systems

Continuous local material model for the mechanical stress-dependency of magnetic properties in non-oriented electrical steel

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