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Abstract
In high-speed electrical machines (HSEM), mechanical vibration associated with critical speeds of rotor systems can be detrimental to the machine operational stability, especially for vibration near resonances. The structural sizing of a rotor system is often constrained to its mechanical parameters, such as its overall weight, maximum torque, and rated power, which complicate the design, necessitating an iterative design optimization process. This work presents a systematic and iterative rotor structural sizing optimization methodology that incorporates semi-analytical and numerical modeling, specifically taking into account multiple mechanical design parameters from the static, rotordynamic, and electromagnetic-thermal evaluation. The proposed methodology provides an effective design optimization procedure for a general application of HSEM to accelerate its design process, by which the power density and the dynamics stability during high-speed operation are optimized simultaneously. A parametric analysis was carried out where a 24-kW, 12,000-rpm aviation starter-generator was optimized. It was demonstrated that the power density of the machine could be increased by 14.7% from 2.3 to 2.6 kW/kg, while the critical speed was increased by 128.6% from 1,400 to 3,200 Hz.
Acknowledgments
The authors acknowledge the support received from Ningbo Natural Science Foundation (Project ID 2022J176) China and Ningbo Key Laboratory on Energy Material and Technology. This work was partially supported by the PF42 project of the Propulsion Futures Beacon of the University of Nottingham.
Disclosure statement
The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.