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Mechanical Design of Electric Motors
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Table of Contents

Preface
List of Symbols
Introduction of Electric Motors
History of Electric Motors
Motor Design Characteristics
Classifications of Electric Motors
Motor Design and Operation Parameters
Sizing Equations
Motor Design Process and Consideration
Motor Failure Mode
IP Code
Rotor Design
Rotor in Induction Motor
Permanent Magnet Rotor
Rotor Manufacturing Process
Rotor Dynamic Balancing
Interference Fit
Stress Analysis of Rotor
Rotordynamic Analysis
Rotor Burst Containment Analysis
Shaft Design
Shaft Materials
Shaft Loads
Shaft Design Methods
Engineering Calculations
Shaft Design Issues
Stress Concentration
Torque Transmission through Mechanical Joints
Fatigue Failure: Alternative Loading
Shaft Manufacturing Methods
Shaft Misalignment between Motor and Driven Machine
Shaft Coupling
Stator Design
Stator Lamination
Magnet Wire
Stator Insulation
Manufacturing Process of Stator Core
Stator Encapsulation and Impregnation
Stator Design Considerations
Mechanical Stress of Stator
Motor Frame Design
Types of Motor Housing
Testing Methods of Casted Motor Housing
Eedbell Manufacturing
Motor Assembly Methods
Fastening System Design
Anti-Corrosion of Electric Motor and Components
Motor Bearing
Bearing Classification
Bearing Design
Bearing Fatigue Life
Bearing Failure Mode
Bearing Noise
Bearing Selection
Bearing Performance Improvement
Motor Power Losses
Power Losses in Windings Due to Electric Resistance in Copper Wires
Eddy Current and Magnetic Hysteresis Losses
Mechanical Friction Losses
Windage Losses
Stray Load Losses
Motor Cooling
Introduction
Conductive Heat Transfer Techniques
Natural Convection Cooling with Fins
Forced Air Cooling Techniques
Liquid Cooling Techniques
Phase-Change Cooling Techniques
Radiative Heat Transfer
Other Advanced State-of-the-Art Cooling Methods
Motor Vibration and Acoustic Noise
Vibration and Noise in Electric Motor
Fundamentals of Vibration
Electromagnetic Vibrations
Mechanical Vibrations
Vibration Measurements
Vibration Control
Fundamentals of Acoustic Noise
Noise Types and Measurements for Rotating Electric Machines
Motor Noise Abatement Techniques
Motor Testing
Motor Testing Standards
Testing Equipment and Measuring Instruments
Testing Load Level
Testing Methods
Off-Line Motor Testing
Online Motor Testing
Modeling, Simulation, and Analysis of Electric Motors
Computational Fluid Dynamics and Numerical Heat Transfer
Thermal Simulation with Lumped-Circuit Modeling
Thermal Analysis using Finite Element Method
Rotordynamic Analysis
Static and Dynamic Stress/Strain Analysis
Fatigue Analysis
Torsional Resonance Analysis
Motor Noise Prediction
Buckling Analysis
Thermally-Induced Stress Analysis
Thermal Expansion and Contraction Analysis
Innovative and Advanced Motor Design
High Temperature Superconducting Motor
Radial-Flux, Multi-Rotor, or Multi-Stator Motor
Axial-Flux, Multi-Rotor, or Multi-Stator Motor
Hybrid Motor
Conical Rotor Motor
Transverse-Flux Motor
Reconfigurable Permanent Magnet Motor
Variable Reluctance Motor
Permanent Magnet Memory Motor
Adjustable and Controllable Axial Rotor/Stator Alignment Motor
Piezoelectric Motor
Advanced Electric Machines for Renewable Energy
Micromotor and Nanomotor
References

About the Author

Wei Tong, Ph.D, PE is chief engineer at Kollmorgen Corporation, a subsidiary of Danaher Corporation, Radford, Virginia, USA. He is an internationally recognized expert on mechanical-electrical-thermal systems. A fellow of the American Society of Mechanical Engineers and a registered professional engineer in the state of Virginia, USA, Dr. Tong holds 28 US patents and 16 foreign patents. He presently serves as an associate editor of ASME Journal of Heat Transfer and International Journal of Rotating Machinery.

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