Conference: 2026 한국자동차공학회 춘계학술대회
Authors: 황윤재, 김재현, 곽병길, 임명섭
DOI:
In Permanent Magnet assisted Synchronous Reluctance Motors (PMaSynRMs), designing ribs and bridges int the rotor involves a trade-off between structural integrity and magnetic flux leakage. Traditionally, a safety factor of 1.2 is used to prevent mechanical failure, but it fails to quantitatively account for manufacturing uncertainties. To address this, the present study evaluates the structural integrity of a 3-layer fluid-type PMaSynRM rotor using the Conditional Value at Risk (CVaR) technique. To probabilistically evaluate the stress in the rotor, 2D finite element analysis is performed on 10,000 samples generated via Generalized Latin Hypercube Sampling with an independent ±0.1 mm tolerance assigned to the ribs, bridges, and fillets. Under the maximum speed of 10,000 rpm, the CVaR99%, representing the expected value of the top 1% extreme stresses, is calculated as 416.5 MPa. Specifically, although the nominal model was deterministically designed to limit the maximum stress to 350 MPa, the probabilistic distribution demonstrates that the predefined margin successfully accommodates the stress fluctuations induced by manufacturing errors. This result probabilistically verifies that the conventional safety factor of 1.2 is a valid design criterion. By aligning closely with the material's yield stress of 420 MPa, the result ensures rotor’s reliability against the worst-case combinations of manufacturing tolerances without performance loss.