This paper analyzes the impact of the numbers of stator slots and rotor layers on the optimal design of synchronous reluctance (SyR) machines. Eighteen SyR machine examples have been designed by means of a multi-objective optimization algorithm and finite element analysis so to maximize torque and minimize torque ripple. Twelve, twenty-four and forty-eight slot stators are considered, associated to rotors with four-poles and one to six flux barriers per pole. The results of the comparative analysis show that high numbers of slots and layers are beneficial for maximizing the torque and the power factor, and that torque ripple and iron loss minimization require precise matches between the slots and the layers, which are not necessarily the same for the two purposes. Finally, for some slot/layer combinations the optimization algorithm produces nonconventional barrier distributions, very promising is some cases. A fast finite element evaluation is used for the evaluation of thousands of candidate machines during the optimization, whereas an accurate transient with motion finite element analysis stage is used for the off-line characterization of the final designs.

An important barrier to the adoption and acceptance of synchronous reluctance (SyR) machines in different applications lies in their non-standardized design procedure. The conflicting requirements incurring at high speeds among electromagnetic torque and structural and thermal limitations can significantly influence the machine performance, leading to a real design challenge. Analytical models used for design purpose lack in accuracy and force the designer to heavily rely on finite element analysis (FEA), at least during the design refinement stage. This becomes even more computationally expensive as the speed increases, as the evaluation of the rotor structural behaviour is required. This work presents a computationally efficient hybrid analytical-FE design process able to consider all the main limiting design aspects of SyR machine incurring at high speed, namely structural and thermal. As a vessel to investigate the proposed design routine accuracy, several high speed SyR machines have been designed for a wide range of operational speeds (up to 70 krpm). The thermal and mechanical factors limiting the high speed operation are deeply analyzed aiming at maximize the mechanical output power. The proposed design approach is then validated by comparison against experimental measurements on a 5 kW-50 krpm SyR prototype.

This paper describes the design procedure followed to realize a high-speed synchronous reluctance machine for aeronautical application. The attention is mainly focused on the rotor design that is the most critical part of any synchronous reluctance machine; in particular for high-speed applications. After a preliminary optimization of the rotor geometry, a multiphysical design that considered mechanical, thermal, and electromagnetic properties was developed. The main steps of the design procedure together with an extensive analysis of the final design are presented here. Two prototypes have been realized using different rotor lamination materials in order to validate the design procedure.

The design of synchronous reluctance machines with and without permanent magnets assistance constitutes a challenging engineering task due to the numerous design variables and performance indexes to be considered. The design complexity increases even further when the application requires high speed operation, with consequent rotor structural constraints and and related effects on the electromagnetic performance. Structured as two-parts companion papers, this first part proposes a comprehensive design procedure able to consider all the non-linear aspects of the machine behaviour, greatly reducing the number of independent design variables, without worsening the computational burden. In particular, the non linear behaviour of the rotor iron ribs and the effect of the permanent magnets on the structural design are all taken into account with the proposed iterative design procedure targeting the achievement of a desired power factor. The proposed method will be then used to draw some preliminary design considerations highlighting the several trade-offs involved in the design of high speed permanent magnet assisted synchronous reluctance machine. Part I is setting the theoretical bricks that will be further expanded and experimentally validated in the companion paper Part II.

Surface permanent magnet synchronous machines are one of the most widely adopted machine topologies in high-speed applications where efficiency and power factor cannot be compromised. Although the design of such machine type has been extensively investigated in both industry and academia, this work aims at addressing its limitations when applied in high-speed applications. First, this paper proposes an accurate design methodology for continuous-duty high-speed surface-mounted permanent magnets synchronous machines, capable of accounting for the rise of the speed-dependent losses and structural needs with a limited impact on the computational burden. The outlined approach can be used to speed-up the initial design stage as it allows to reduce the number of solutions to evaluate before commencing the refinement stages required before the definition of the final design. Indeed, the introduced design approach is used to systematically assess the maximum power capability as function of the maximum speed and the airgap thickness for a given outer envelope and cooling system. The influence of the high-speed limiting factors is deeply investigated also considering their effects on the machine geometries providing the highest torque. The selection of the final design is discussed and justified. Experimental results of the 4.2 kW-80 kprm prototype validate the design methodology.

This article presents a comprehensive comparative design exercise of synchronous reluctance (SyR) machines considering different soft magnetic materials and a wide range of speeds. First, a general design methodology able to consider all the consequences of selecting different materials is presented. In fact, magnetic nonlinearities, rotor structural limitations, and the rise of both stator and rotor iron losses are all considered. The adopted design approach allows achieving optimal stator and rotor geometries balancing all these competitive multiphysics aspects and keeping constant the cooling system capability. Both silicon–iron (SiFe) and cobalt–iron (CoFe) alloys with optimized magnetic and mechanical performance are examined to assess the maximum capabilities achievable with an SyR machine technology. The adoption of CoFe alloys leads to machines that outperform the SiFe counterparts up to a certain speed, above which, machines with SiFe provide better performance. Indeed, in the lower speed range, the effect of the higher saturation flux density of the CoFe materials is dominant, while for higher design speeds, their higher iron losses and lower yield strength, with respect to the SiFe ones, make the latter more convenient. All the design considerations are finally validated by comparing the predicted performance with the experimental test results on a 6.5-kW, 80-kr/min SyR machine prototype.