| This thesis presents a synchronous reluctance motor/alternator design for a flywheel energy storage system. The goal of this project is to provide an inexpensive alternative to permanent magnet machines in this application. Key design criteria for the machine are high power output at high speeds with high efficiency and low rotor losses.; The proposed rotor design consists of alternating layers of ferromagnetic and nonmagnetic steels which are bonded together using a high-strength bonding process such as brazing or explosive bonding. Analytical expressions are developed to calculate the direct and quadrature inductances, as wen as maximum output torque and maximum-power-factor torque, of this design. These expressions are then used to design rotors with optimized performance.; A two-dimensional finite element simulator has been developed in MATLAB which calculates the steady-state eddy currents induced in the rotor at a given operating point. Results from the simulator suggest that a machine design with manageable rotor losses can be achieved.; Stator and rotor design criteria are developed and combined in the formulation of a design process for high-speed synchronous reluctance machines. Two prototype machines, designed to provide 60kW over a speed range of 24,000–48,000rpm, have been constructed along with two 400V , 200A inverters. A stator-flux-oriented torque controller with an optimal-efficiency algorithm has been developed to drive the machines. Experimental results largely validate the design process, except that core losses in the stator iron were significantly higher than expected. Nevertheless, efficiencies of up to 91% were achieved at a 10kW, 10,000rpm operating point with estimated rotor losses less than 0.5% of total input power. |
