Combined electromagnetic and mechanical design optimization of interior permanent magnet rotors for electric vehicle drivetrains

In many high-speed electrical machines, centrifugal forces within the rotor can be first-order constraints on electromagnetic optimization. This can be particularly acute in interior permanent magnet (IPM) machines in which magnets are usually retained entirely by the rotor core with no additional mechanical containment. This study investigates the nature of the trade-off between mechanical and electromagnetic requirements within the context of an eight-pole, 100 kW IPM machine with a base speed of 4000 rpm and an extended speed range up to 12,000 rpm. A series of mechanical and electromagnetic models are used to estimate the level of shaft interference, mechanical stress in critical regions of the rotor and the impact of various features and dimensions within the machine on electromagnetic torque. A systematic exploration of the design space is undertaken for rotor diameters from 120 mm to 180 mm, with optimal designs in terms of torque per unit length established at each diameter while meeting the constraints imposed on mechanical stress. The final preferred design has a rotor of 165 mm and an axial length of 103 mm long with a fractional slot winding in a 30-slot stator. The overall machine has an active mass of 42.3 kg, which corresponds to ~2.4 kW/kg. This paper describes the optimization study in detail and draws on the results to explore the nature of the design trade-offs in such rotors and the impact of core properties.