A high-performance 640-kW 10.000-rpm Halbach-array PM slotless motor with active magnetic bearings. Part II: Manufacturing and testing

Abstract

The ongoing gas industry expansion calls for quick and strong advances in turbomachinery-coupled highspeed electric motors. Very high efficiency, dynamic performance and reliability are among the main requirements to be met at competitive costs by electric machine suppliers. This paper reports on an industrial R&D project aimed at finding the best compromise between performance targets and production cost reduction through the realization of a 640-kW 10.000-rpm PM motor prototype. The preliminary and optimization design of the motor have been covered in a companion paper (Part I). Here the manufacturing and testing of the prototype are covered. The main technology challenges encountered throughout the manufacturing process are addressed. Furthermore, the paper reports on the testing campaign conducted on the motor under converter supply and in different load and speed conditions. The prototype testing was successful and proved the possibility to reach and exceed a 98% motor efficiency target with affordable costs and available technologies.