Mechanical design considerations for conventionally-laminated, high-speed, interior PM synchronous machine rotors

This paper discusses mechanical design considerations that are particular to conventionally (i.e., radially) laminated rotors of interior permanent-magnet synchronous machines. Focus is placed on applications where the radial forces due to high-speed operation are the major mechanically limiting design factor. Proper design of the lamination bridges, or ribs, at the rotor outer diameter is explained in terms of the both material considerations and electromagnetic performance impact. The tradeoff of complexity versus performance associated with using strengthening ribs in the magnet cavities is discussed. The sensitivity of the mechanical design limitations to the rotor-shaft mounting mechanism is also highlighted. These effects are then analyzed using finite element analysis for a 150 Nm/6kW integrated starter/alternator designed for operation up to 6000 rpm with an annular rotor to accommodate a torque converter or clutch assembly. This example demonstrates that it is possible to significantly improve the rotor's structural integrity using the techniques described in this paper with only a very modest impact on the projected machine drive cost.