Mechanical Design of Electric Motors: 1st Edition (Hardback) book cover

Mechanical Design of Electric Motors

1st Edition

By Wei Tong

CRC Press

736 pages | 492 B/W Illus.

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Rapid increases in energy consumption and emphasis on environmental protection have posed challenges for the motor industry, as has the design and manufacture of highly efficient, reliable, cost-effective, energy-saving, quiet, precisely controlled, and long-lasting electric motors.

Suitable for motor designers, engineers, and manufacturers, as well as maintenance personnel, undergraduate and graduate students, and academic researchers, Mechanical Design of Electric Motors provides in-depth knowledge of state-of-the-art design methods and developments of electric motors. From motor classification, design of motor components, model setup, and material and bearing selections to power losses, motor cooling, design integration, vibration, and acoustic noise, this comprehensive text covers the fundamentals, practical design and design-related issues, modeling and simulation, engineering analysis, manufacturing processes, testing procedures, and performance characteristics of electric motors today.

Focusing on the mechanical design of modern electric motors, the book:

  • Details the design and manufacture of major components and subsystems, such as rotors, shafts, stators, and frames
  • Reviews various cooling techniques, including forced air, liquid, and phase-change
  • Discusses the analysis and calculation of motor power losses
  • Addresses motor vibration and acoustic noise issues
  • Presents engineering analysis methods and case study results
  • Emphasizes construction, optimization, and applications

Featuring research results from the author’s own personal experience and the significant contributions of others, Mechanical Design of Electric Motors highlights innovative and advanced electric motors developed in recent decades.

Table of Contents


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


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


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.

Subject Categories

BISAC Subject Codes/Headings:
TECHNOLOGY & ENGINEERING / Industrial Design / General
TECHNOLOGY & ENGINEERING / Industrial Design / Packaging