Thermo-Mechanical Rotor Fatigue of an Interior Permanent Magnet Synchronous Motor

Interior permanent magnet motors (IPMSMs) are extensively used as traction motors today because of their exceptional torque and power density, and wide constant power operating range. Under real-world usage, an IPMSM rotor undergoes varying electromagnetic, thermal, and mechanical loads. Under such conditions, fatigue life-based design criteria should be utilized over stress-based design criteria to ensure the structural integrity of the rotor. Moreover, the driving dynamics can change the rotor temperature continuously, which affects the electromagnetic, mechanical, and fatigue properties of rotor material. This paper proposes a robust thermo-mechanical rotor fatigue simulation workflow considering the significant loads acting on an IPMSM rotor and the temperature variation throughout a drive cycle. It discusses an accelerated fatigue life estimation approach based on peak valley extraction to reduce the simulation time significantly for stress and fatigue analysis. Then, it presents a method for stress-life curve generation for a variable loading. It also presents a sensitivity study with a median S-N curve, and a 90%-reliability 95%-confidence (R90C95) S-N curve.