Design and Electromagnetic-Mechanical Coupled Analysis of a Wrapped Interior Permanent Magnet Synchronous Motor

An interior permanent magnet synchronous motor (IPMSM) rotor equipped with a carbon-fiber-reinforced plastic (CFRP) sleeve, based on an electromagnetic–mechanical coupled analysis approach, was designed and analyzed. As the demand for high-speed traction motors increases, addressing the excessive rotor stress caused by higher rotational speeds has become critical. To mitigate this issue, a CFRP sleeve is used to enhance mechanical strength while minimizing the impact on electromagnetic performance. However, the introduction of the CFRP sleeve increases design complexity because of changes in air gap length and structural constraints. The crucial considerations required in the design and manufacturing processes, including tradeoffs between mechanical integrity and magnetic performance, are discussed. The proposed design methodology differentiates the rotor structure from conventional IPMSMs, offering a viable solution for high-speed, high-power-density motor applications.