Design and Experimental Evaluation of a High Specific Power Permanent Magnet Synchronous Machine

As a learning step to gain experience in designing high specific power electric machines for demanding applications such as aircraft propulsion, this paper presents research results in the design, fabrication, and experimental testing of a scaled-down 300-kW electric machine. With advanced structure and materials, this machine achieves an active-material specific power of 14.4 kW/kg and an electromagnetic efficiency of 99.2% under full load condition using finite element analysis. The mechanical integrity of the rotor is fully validated at the rated speed of 17, 000 rpm in finite element analysis. The fabricated machine prototype is mounted onto a 350-hp dynamometer for comprehensive performance characterization. The efficiency of the machine prototype is mapped based on the experimental measurements under various operating conditions. In this paper, the electromagnetic analysis, trade-offs at the design stage, mechanical stability considerations, and experimental testing results are summarized and presented in detail.