Recommendation for building me a 500kW PMSM motor prototype

[philks01]

I'm looking to refine a motor design for a 500kW Ferrite PMSM motor, and then build my first prototypes. Ferrite magnets are required to achieve extremely low rotor loss as this motor must power a large flywheel in a vacuum. Can anyone point me to a motor manufacturer capable of taking on such a project?

The motor is potentially a traditional PMSM design preferably with an inside rotor. I'm looking at 8 poles,(2" thick magnets), bound to the rotor possibly with S-glass wrap. Overall motor is 28" diameter, 15" D. rotor, 13" stack height.

 

[Skogsgurra]

What speed will you be running at?

Gunnar Englund

http://www.gke.org

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100 % recycled posting: Electrons, ideas, finger-tips have been used over and over again...

 

[sreid]

You can ask Carlsbad Magnetics.

http://www.carlsbadmagnetics.com/

 

[philks01]

Here is some performance data to help clarify the design:
The max motor speed is 6400 rpm, and the normal operating range for continuous 500kW charge/discharge is between 40% to 100% speed. My preliminary design was performed using Infolytica MotorSolve software and it shows a peak line-line voltage of 2kV for full speed; I anticipate using a 2300 kV DC bus. Currents would vary from 600 Arms at 40% speed down to 225 Arms at full speed to maintain 500 kW. Stator losses are near 8kW, however rotor losses are amazingly small < 30 Watts. I can remove the stator heat easily if the stator is on the outside.

 

[Skogsgurra]

Sounds like you are going to use variable frequency for the stator. Have you included the extra rotor losses caused by the PWM in the 30 watts?

Also, if there is not a perfect match between the (preferably) sine-shaped flux wave and the rotor flux, you will have additional hysterisis and also some eddy current losses.

The latter are small because of high resistivity in the ferrite material. But hysterisis losses can be quite high if fluxes do not match perfectly.

Gunnar Englund

http://www.gke.org

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100 % recycled posting: Electrons, ideas, finger-tips have been used over and over again...