Interior permanent magnet synchronous motors (IPMSMs) are extensively used as traction motors today because of their exceptional torque, power density, and wide, constant power operating range. Under real-world usage, an IPMSM rotor undergoes varying electromagnetic, thermal, and mechanical loads. Under such conditions, fatigue life-based design criteria should be used over stress-based design criteria to ensure the structural integrity of the rotor. Moreover, the driving dynamics can change the rotor temperature continuously, which affects the electromagnetic, mechanical, and fatigue properties of the rotor material. This paper proposes a robust thermomechanical rotor fatigue simulation workflow considering significant loads acting on an IPMSM rotor and the temperature variation throughout a drive cycle. It discusses an accelerated fatigue life estimation approach based on the peak valley extraction method to reduce the simulation time significantly for the stress and fatigue analysis. Then, it presents a method for a stress-life curve generation for variable loading. It also presents a sensitivity study with a median S-N curve, and a 90% reliability and 95% confidence (R90C95) S-N curve.

Interior permanent magnet motors (IPMSMs) are extensively used as traction motors today because of their exceptional torque and power density, and wide constant power operating range. Under real-world usage, an IPMSM rotor undergoes varying electromagnetic, thermal, and mechanical loads. Under such conditions, fatigue life-based design criteria should be utilized over stress-based design criteria to ensure the structural integrity of the rotor. Moreover, the driving dynamics can change the rotor temperature continuously, which affects the electromagnetic, mechanical, and fatigue properties of rotor material. This paper proposes a robust thermo-mechanical rotor fatigue simulation workflow considering the significant loads acting on an IPMSM rotor and the temperature variation throughout a drive cycle. It discusses an accelerated fatigue life estimation approach based on peak valley extraction to reduce the simulation time significantly for stress and fatigue analysis. Then, it presents a method for stress-life curve generation for a variable loading. It also presents a sensitivity study with a median S-N curve, and a 90%-reliability 95%-confidence (R90C95) S-N curve.

This paper introduces a direct oil cooling concept for rotor coils of an electrically excited synchronous propulsion motor. The proposed approach utilizes a hollow shaft and two distinct laminations to guide non-conductive, ultra-low-viscosity automotive oil onto the rotor coils. Radial channels are positioned at the rotor center to transfer oil from the hollow shaft to the axial channels at the outer surface of the rotor. Axial channels direct the coolant from the radial channels and splash it onto the rotor end windings. The proposed approach enhances the thermal management of the heat generated by rotor coils, and helps improve the motor performance and power density. Computational fluid dynamics (CFD) simulations were conducted to analyze the effectiveness of the cooling method under various operating conditions.