Mechanical design and validation of 1 MW permanent magnet synchronous machine (PMSM)

This thesis focuses on a high frequency, high power density (8 hp/lb), 1 MW power output electric motor design to double the power density of electric machines, bringing us closer to electrified propulsion. This thesis focuses on the mechanical analysis and design for a specially designed 1 MW permanent magnet synchronous electric machine. First of all the design intention or design topology will be explained. A high speed, high frequency, permanent magnet synchronous machine is designed. An inside-out configuration was chosen for its high peak efficiency and large tip speed. There are also other innovative designs such as Halbach array magnets and air gap windings. Combination of these designs does impose challenges for the mechanical design of the motor. Not only does mechanical integrity like strength need to be considered, but dynamic performance, vibration and thermal performance would also face more challenges when it comes to actual operation. The thesis will first go over some trade-off study and analysis before we introduce our design. Then the thesis mainly addresses analysis for rotor dynamics as well as fan performance. Design challenges are analyzed by analytical equations, numerical methods like finite element analysis and finally test results