Rotor design of a high-speed Permanent Magnet Synchronous Machine rating 100,000 rpm at 10kW

Rotors of electrical high speed machines are subject to high stress, limiting the rated power of the machines. This paper describes the design process of a high-speed rotor of a Permanent Magnet Synchronous Machine (PMSM) for a rated power of 10 kW at 100,000 rpm. Therefore, at the initial design the impact of the rotor radius to critical parameters is analyzed analytically. In particular, critical parameters are mechanical stress due to high centrifugal forces and natural bending frequencies. Furthermore, air friction losses, heating the rotor and the stator additionally, are no longer negligible compared to conventional machines and must be considered in the design process. These mechanical attributes are controversial to the electromagnetic design, increasing the effective magnetic air gap, for example. Thus, investigations are performed to achieve sufficient mechanical strength without a significant reduction of air gap flux density or causing thermal problems. After initial design by means of analytical estimations, an optimization of rotor geometry and materials is performed by means of the finite element method (FEM).