Design of a 3kW 150k RPM super high-speed permanent magnet synchronous motor

This paper discusses the design procedure of a super high speed permanent magnet synchronous machine. A 3kW radial PMSM designed for operation up to 150,000 r/min is proposed in the paper. Thanks to the super high speed, the designed motor can achieve high energy density at 2.5 kW/kg(housing weight included) and efficiency is over 97%. The super high speed brings challenges both on electrical design and mechanical design. Proper design of the stator lamination, including bore diameter, outer diameter, slot, yoke thickness and airgap is explained. At high frequency, proximity effect and skin effect becomes significant, the effects have been analyzed and multi-strand Litz wires are chosen for this design. Double-layer distributed winding is used instead of concentric winding to reduce the harmonic EMF. The rotor structure is designed to endure the mechanical stress at high RPM. The design is optimized in ANSYS Maxwell and simulation results verified the performance of the motor. A controller for the high speed drive has been developed for the motor.