A Method for Analyzing the Stress of Surface-Mounted PM Rotor Wound by Carbon Fiber Layers for High-Speed Machine

Abstract

This article proposed a method for analyzing the stress of surface-mounted permanent magnet (PM) rotor wound by carbon fiber (CF) layers of high-speed machine. First, the stress model of the traditional three-layer PM rotor is analyzed. Second, the stress model of the PM rotor wrapped by multilayers of CF is established based on the three-layer rotor. The tension control design method based on interference iteration is investigated, and the analysis process is illustrated. Third, a finite element analysis (FEAs)-based interference control method (ICM) for CF winding process simulation is proposed and compared with the stress analysis strategy based on the equivalent temperature field method (ETFM). The advantages of the proposed FEA-based ICM are highlighted. Finally, a CF would PM rotor with a rated speed of 50000 r/min is designed and manufactured. The overspeed test at 1.2 times rated speed is conducted to verify the rationality of analyses. The results show that compared with FEA-based ETFM, the proposed FEA-based ICM has higher accuracy in calculating stress of rotor wound by CF layers.