Integrated Design of a High Speed Magnetic Levitated Brushless Direct Current Motor System

High speed magnetic levitated brushless direct current motor system mainly consists of a motor, a rotor and two magnetic bearings. New ideas demonstrate advances in the design of integration interface and selection of the dynamic design parameters. In this paper, integrated design procedure is interpreted, considering the structural, electromagnetic and thermal aspects with their contradiction and integration. The motor design is set as the initial design entrance to determine its stator diameters with other key parameters as dynamic design parameters. Then, magnetic bearing design is set as the interface for rotor, with magnetic bearings' diameters and lengths determined. So, all the dynamic parameters will be specified considering rotor dynamics and the corresponding strength/thermal analysis. Finally, several validations including finite element method and experiment, have been carried out. Prototype of this maglev motor system has been designed and manufactured, with sufficient experiment processes validated. It rotates over 55,332 rpm under load with drag system, corresponding to above design results.