Details
| Original language | English |
|---|---|
| Title of host publication | 2021 IEEE International Electric Machines and Drives Conference, IEMDC 2021 |
| Publisher | Institute of Electrical and Electronics Engineers Inc. |
| ISBN (electronic) | 9781665405102 |
| ISBN (print) | 978-1-6654-4628-0 |
| Publication status | Published - 2021 |
| Event | 2021 IEEE International Electric Machines and Drives Conference, IEMDC 2021 - Hartford, United States Duration: 17 May 2021 → 20 May 2021 |
Abstract
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.
Keywords
- additive manufacturing, laser beam melting, permanent magnet synchronous machine, rotor skewing
ASJC Scopus subject areas
- Energy(all)
- Energy Engineering and Power Technology
- Engineering(all)
- Electrical and Electronic Engineering
- Engineering(all)
- Mechanical Engineering
- Engineering(all)
- Safety, Risk, Reliability and Quality
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2021 IEEE International Electric Machines and Drives Conference, IEMDC 2021. Institute of Electrical and Electronics Engineers Inc., 2021. 9449566.
Research output: Chapter in book/report/conference proceeding › Conference contribution › Research › peer review
}
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 -