Efficiency Optimization of a 100-W 500 000-r/min Permanent-Magnet Machine Including Air-Friction Losses

This paper proposes a method for the efficiency optimization of ultrahigh-speed permanent-magnet machines. Analytical methods are applied for the modeling of the machine that is equipped with a diametrically magnetized rotor and a slotless stator. The outer dimensions of the machine are design constraints, and the internal dimensioning is optimized for minimum losses. The air-friction losses are taken into account in addition to the usual iron, copper, and eddy-current losses. Laminated silicon-iron or laminated amorphous iron is used as the stator core material. The results show that air-friction losses influence the optimum design considerably, leading to a small rotor diameter at high speeds. The loss minimization and the amorphous iron core make it possible to reduce the calculated losses by 63% as compared to a machine design not considering air-friction losses. The resulting efficiency is 95% for a 100-W 500 000-r/min machine excluding bearing losses. Experimental results are shown to illustrate the validity of the method.