TY - GEN

T1 - Design and Experimental Investigation of an Additively Manufactured PMSM Rotor

AU - Urbanek, Stefan

AU - Frey, Pauline

AU - Magerkohl, Sebastian

AU - Zimmer, Detmar

AU - Tasche, Lennart

AU - Schaper, Mirko

AU - Ponick, Bernd

N1 - Funding Information: This work was supported by the German Research Association (Deutsche Forschungsgemeinschaft, DFG) under the project ’Additive Manufacturing of electric machines: Research on the potential of additive manufacturing of PM synchronous machine rotors’ (’Additive Fertigung im Elektromaschinenbau: Erforschung von Potentialen der additiven Fertigung in Rotoren permanent-magneterregter Synchronmaschinen’).

PY - 2021

Y1 - 2021

N2 - This paper describes the design, construction and manufacturing process of an additively manufactured (AM) permanent magnet synchronous rotor with interior magnets. After this, the AM rotor is mounted into a conventional stator and tested under load and no-load. The rotor active part is manufactured from soft-magnetic ferro-silicon alloy using the powder bed-based AM technology of laser beam melting (LBM). The so-called AM functional rotor model is both designed with extended functionality and with an increased lightweight level. Therefore, the functional model is continuously skewed and its performance is compared to a non-skewed and a step-skewed rotor. In order to reduce eddy current losses, the surface of the functional model was grooved. Furthermore, a new design of the rotor end section is presented. The weight and the inertia of the rotor are reduced by implementing lightweight AM structures, a hollow shaft and a new conical transition region between the active part and the bearings. The building process and design adjustments in order to ensure a robust additive manufacturing process are presented, too. Finally, measurements show that this new design significantly reduces the amplitude of the torque ripple. In summary, the torque of the motor is increased and the mechanical time constant is decreased by inertia reduction.

AB - This paper describes the design, construction and manufacturing process of an additively manufactured (AM) permanent magnet synchronous rotor with interior magnets. After this, the AM rotor is mounted into a conventional stator and tested under load and no-load. The rotor active part is manufactured from soft-magnetic ferro-silicon alloy using the powder bed-based AM technology of laser beam melting (LBM). The so-called AM functional rotor model is both designed with extended functionality and with an increased lightweight level. Therefore, the functional model is continuously skewed and its performance is compared to a non-skewed and a step-skewed rotor. In order to reduce eddy current losses, the surface of the functional model was grooved. Furthermore, a new design of the rotor end section is presented. The weight and the inertia of the rotor are reduced by implementing lightweight AM structures, a hollow shaft and a new conical transition region between the active part and the bearings. The building process and design adjustments in order to ensure a robust additive manufacturing process are presented, too. Finally, measurements show that this new design significantly reduces the amplitude of the torque ripple. In summary, the torque of the motor is increased and the mechanical time constant is decreased by inertia reduction.

KW - additive manufacturing

KW - laser beam melting

KW - permanent magnet synchronous machine

KW - rotor skewing

UR - http://www.scopus.com/inward/record.url?scp=85112796332&partnerID=8YFLogxK

U2 - 10.1109/IEMDC47953.2021.9449566

DO - 10.1109/IEMDC47953.2021.9449566

M3 - Conference contribution

AN - SCOPUS:85112796332

SN - 978-1-6654-4628-0

BT - 2021 IEEE International Electric Machines and Drives Conference, IEMDC 2021

PB - Institute of Electrical and Electronics Engineers Inc.

T2 - 2021 IEEE International Electric Machines and Drives Conference, IEMDC 2021

Y2 - 17 May 2021 through 20 May 2021

ER -