High speed synchronous reluctance motor design for industrial applications

Electric motors used in industrial applications are critically important for energy efficiency, high performance, and cost-effectiveness. Spindle motors are widely employed in CNC machines and precision machining systems due to their high-speed operation, low vibration, and precision characteristics. However, their complex structure, cooling mechanisms, and maintenance requirements make them costly and challenging to manage. On the other hand, synchronous reluctance motors have gained prominence in sustainability-focused applications due to their magnet-free designs, low losses, and high energy efficiency. Nevertheless, the production and operation of these motors involve additional challenges due to the complexity of magnetic circuit design and the need for precise control algorithms. This study aims to develop a hybrid motor design by combining the high-speed and precision advantages of spindle motors with the energy efficiency and low maintenance requirements of synchronous reluctance motors. Following magnetic circuit, torque, and efficiency analyses performed using the Ansys Maxwell simulation software, a physical prototype of the design was produced, and its performance was comprehensively evaluated through rigorous testing. The results, supported by both theoretical and experimental findings, demonstrate that the hybrid motor design offers an innovative and sustainable solution for industrial applications by providing energy efficiency and performance optimization.