Design and Experimental Verification of a 50 kW Interior Permanent Magnet Synchronous Machine

This paper presents the design details for an IPM machine designed to deliver 50 kW constant power over a 5:1 speed range extending from 850 rpm to 4250 rpm, with a gradual reduction in the required output power up to 8000 rpm (25 kW). Electromagnetic, thermal, and structural considerations have been included in the design optimization process. The resulting machine is designed with two magnet layers per pole and a distributed stator winding. Special features of the machine include its deep stator slots and four-layer winding, made necessary by the desire to minimize the machine's moment of inertia. Test results available to date demonstrate that the machine is capable of delivering the required output torque and power, and the agreement between the predicted and measured machine parameters is generally quite good. Calculated iron losses for high-speed flux-weakening operation are presented in the final section of the paper, illustrating the challenges associated with minimizing the impact of high-frequency harmonic flux density components.