energies
Review
Research on Stress Design and Manufacture of the
Fiber-Reinforced Composite Sleeve for the Rotor of High-Speed
Permanent Magnet Motor
Wuqiang Wang, Yong Li *, Dajun Huan, Xiaodong Chen, Hongquan Liu, Yanrui Li and Lisha Li






Citation: Wang, W.; Li, Y.; Huan, D.;
Chen, X.; Liu, H.; Li, Y.; Li, L.
Research on Stress Design and
Manufacture of the Fiber-Reinforced
Composite Sleeve for the Rotor of
High-Speed Permanent Magnet
Motor. Energies 2022, 15, 2467.
https://doi.org/10.3390/en15072467
Academic Editor: Adolfo Dannier
Received: 10 March 2022
Accepted: 24 March 2022
Published: 27 March 2022
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Copyright: © 2022 by the authors.
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This article is an open access article
distributed under the terms and
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Attribution (CC BY) license (https://
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4.0/).
Energies 2022, 15, 2467. https://doi.org/10.3390/en15072467
College of Materials Science and Technology, Nanjing University of Aeronautics and Astronautics,
Nanjing 210016, China; wangwuqiang@nuaa.edu.cn (W.W.); huandj@nuaa.edu.cn (D.H.);
xiaodongchen@nuaa.edu.cn (X.C.); liuhongquan@nuaa.edu.cn (H.L.); niyanrui@nuaa.edu.cn (Y.L.);
lls857762634@nuaa.edu.cn (L.L.)
* Correspondence: lyong@nuaa.edu.cn; Tel.: +86-139-5180-5415
Abstract: As a key component to ensure the safety and stability of the surface-mounted permanent
magnet motor rotor, stress research on the sleeve has long been a subject that has attracted researchers.
Fiber-reinforced composite materials have the characteristics of high specific strength, high specific
modulus, and low eddy current loss. The use of a fiber-reinforced composite material sleeve that
can effectively reduce the thickness of the sleeve and structural weight, and can improve the power
density of the motor is an inevitable trend of the development of high-performance permanent
magnet motors. This paper summarizes the matching of fibers and resins of composite materials to
the sleeve: the stress design criteria, stress calculation method, and stress influencing factors of the
composite sleeve; two typical stress-forming methods of the composite sleeve; and the preloading
effect of the sleeve, strength, and rotor prototype performance testing. This paper focuses on the
application of tension winding technology in sleeve forming. Based on the characteristics of composite
material layer synthesis, this method has the advantages of high forming efficiency, small forming
damage, easy realization of stress design, and a high preloading effect. This method can meet the
sleeve-forming requirements of high-performance, large-scale, high-speed permanent magnet motors.
However, the application of the new high-performance material system in the existing research is
insufficient, the research on the technological factors in the tension winding process is scarce, and the
performance testing method after the sleeve preparation is single, which needs further research.
Keywords: motor sleeve; composite material; stress design; prestress manufacturing
1. Introduction
In recent years, soaring energy prices, the intensification of the greenhouse effect, and
the deteriorating situation of energy supply and demand have made energy shortage and
environmental problems become the theme of global energy problems. An alternative
solution is to replace traditional induction motors with high-efficiency permanent magnet
(PM) motors [1]. High-speed motors have the advantages of high power density and can
be directly connected to high-speed loads, which improves the efficiency and reliability of
the motor system and reduces energy consumption. Turbines and other fields have been
widely used. Figure 1 illustrates several typical applications of high-speed motors [2].
https://www.mdpi.com/journal/energies
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Energies 2022, 15, x FOR PEER REVIEW 2 of 23
Energies 2022, 15, 2467 2 of 22

(a) (b) (c)

(a) (b) (c) storage systems. Reproduced
Figure 1. Typical application of high-speed motor: (a) flywheel energy
from [2],1.
Figure IEEE Trans.
Typical Ind. Electron.:
application 2013; (b)motor:
ofhigh-speed
high-speed centrifugal compressor
(a)flywheel
flywheel energysystem.
storageReproduced from [3],
systems.Reproduced
Reproduced
Figure 1. Typical application of motor: (a) energy storage systems.
IEEE Trans. Magn.: 2007; (c) aviation machine. Reproduced from [4], Electr. Power Syst.
from [2], IEEE Trans. Ind. Electron.: 2013; (b) centrifugal compressor system. Reproduced from Res.: 2017.
[3],
from [2], IEEE Trans. Ind. Electron.: 2013; (b) centrifugal compressor system. Reproduced from [3],
IEEE Trans. Magn.: 2007; (c) aviation machine. Reproduced from [4], Electr. Power Syst. Res.: 2017.
IEEESurface-mounted
Trans. Magn.: 2007;high-speed
(c) aviation permanent
machine. Reproduced from [4],
magnet motors Electr.
have thePower Syst. Res.:
advantages 2017.
of sim-
ple structure, small loss,high-speed
Surface-mounted and high power permanentdensity, and are
magnet motors a research
have hotspot in theoffield
Surface-mounted high-speed permanent magnet motors have thethe advantages
advantages of simplesim-
ofple
high-speed
structure, motors
small [5]. The
loss, and permanent
high power magnet
density, ofandthe are
surface
a stick permanent
research hotspot in magnet
the field
structure, small loss, and high power density, and are a research hotspot in the field of
motor is considerate
of high-speed motors to the
[5]. surface
The of the rotor
permanent mandrels,
magnet theand the permanent magnet ma-
high-speed motors [5]. The permanent magnet of theof surface surface stick permanent
stick permanent magnetmagnet motor
terial
motorhasishigh compressive
considerate to the strength
surface butthe
of low tensile
rotor strength.
mandrels, andWhen
the the rotor ofmagnet
permanent the motor ma-
is considerate to the surface of the rotor mandrels, and the permanent magnet material has
runs at high
terialcompressive
high speed,
has high compressive the permanent
strength but strength magnet
but low
low tensile cannot bear
tensile strength.
strength. the
When theWhen huge centrifugal
rotorthe rotor
of the load,
of theruns
motor so
motoraat
sleeve
high must
runsspeed,
at high be set
thespeed,outside
permanent the permanent
the permanent
magnet cannot magnet magnet
bearcannot [6].
the huge The
bear sleeve, as
the huge load,
centrifugal the core
centrifugal component
load,must
so a sleeve so a
of the
sleeve rotor
must of the
be surface-mount
set outside the permanent
permanent magnet
magnet motor,
[6]. The
be set outside the permanent magnet [6]. The sleeve, as the core component of the rotor of needs
sleeve, to
as have
the the
core character-
component
istics
of the
the ofrotor
low eddy
surface-mount of thecurrent lossmagnet
surface-mount
permanent andpermanent
high strength
motor, magnet
needs and can the
motor,
to have provide
needs pre-pressure
to have the
characteristics foreddy
the
of character-
low
permanent
istics of magnet
low eddy to ensure
current that
loss the
and rotor
high parts
strengthare not
and separated
current loss and high strength and can provide pre-pressure for the permanent magnetthe
can provide during operation.
pre-pressure for to
Thethat
permanent
ensure high-speed
magnet
the rotorto development
ensure
parts are that of
thethe
rotor
not separated motorparts system
during nothas
areoperation. put forward
separated during higher require-
operation.
mentsThe for high-speed
The motor strength
high-speed design. On
development
development the
of of
the theaspect
motor motor ofsystem
systemsurface mount
has
has put put motor
forwardforward strength
higher higher design,
require-
requirements
the
for rotor
ments
motor sleeve,
for motor
strengthasstrength
adesign.
key component
design.
On Onof the
the aspect the system,
surfaceofhas
ofaspect the motor
surface
mount characteristics
mount motorof
strength high running
strength
design, the design,
rotor
speed,
sleeve, high
the rotor aload-bearing
as sleeve, as a keycapacity,
key component of theand
component oflong-running
system, the has
system, life,the
has leading
the characteristics toofdesign
characteristics and
of manufac-
high
high running running
speed,
turing
speed,
high difficulties.
load-bearing In
high load-bearing recentcapacity,
capacity, years, the
and design
and long-running and
life,manufacture
long-running life, leading
leading of high-speed
to design to design permanent
and manufac-
and manufacturing
magnet motor
turing difficulties.
difficulties. sleeves have
In recentInyears, become
recentthe years, a hot
theand
design issue.
design Common
and manufacture
manufacture sleeve materials
of high-speed include
of high-speed
permanent carbon
permanent
magnet
fiber,
magnet
motor glass fiber,
motorhave
sleeves and
sleeves other high-strength
have become
become fiber-reinforced
a hotCommon
a hot issue. issue. Common composite
sleeve materials
sleeve materials materials.
include includeFigure
carboncarbon 2
fiber,
shows
glass the
fiber,fiber,
glasscarbon
and fiber-reinforced
other
fiber, andhigh-strength composite sleeve rotor
fiber-reinforced
other high-strength used
composite
fiber-reinforced in a brushless
materials.
composite DC (BLDC)
Figure
materials. 2Figure
shows2
machine,
the carbon
shows asfiber-reinforced
the well as fiber-reinforced
carbon high-strength special
composite alloy
sleeve
composite materials
rotor used
sleeve insuch
rotor a used as in
Inconel718
brushless DC (BLDC)
a brushless andDC titanium
machine,
(BLDC)
alloy.
as well as high-strength
machine, special alloy
as well as high-strength materials
special alloysuch as Inconel718
materials and titanium
such as Inconel718 andalloy.
titanium
alloy.

(a) (b) (c)

(a) Figure 2. Carbon fiber-reinforced composite
(b) (c)
Figure 2. Carbon fiber-reinforced composite sleeve
sleeve rotor
rotor used
used in
in BLDC
BLDC machine:
machine: (a)
(a) cross-section
cross-section of
ofFigure
the high-speed
2. Carbon motor; (b) cross-section
fiber-reinforced of the carbon
composite fiber-reinforced composite sleeve perma-
the high-speed motor; (b) cross-section of thesleeve
carbonrotor used in BLDC
fiber-reinforced machine:sleeve
composite (a) cross-section
permanent
nent
of magnet
the rotor; (c)
high-speed carbon
motor; (b)fiber-reinforced
cross-section of composite
the carbon sleeve permanentcomposite
fiber-reinforced magnet rotor. Repro-
sleeve perma-
magnet rotor; (c) carbon fiber-reinforced composite sleeve permanent magnet rotor. Reproduced
duced from [3],rotor;
nent magnet IEEE(c)
Trans. Magn.:
carbon 2007.
fiber-reinforced composite sleeve permanent magnet rotor. Repro-
from [3], IEEE Trans. Magn.: 2007.
duced from [3], IEEE Trans. Magn.: 2007.
For rotors of the same diameter, composite sleeves tend to be thinner than metal
For rotors of the same diameter, composite sleeves tend to be thinner than metal
sleevesFor
androtors
can withstand higher
of the same speeds,composite
diameter, and produce lower
sleeves tendeddy current
to be losses
thinner than[7].metal
At
sleeves and can withstand higher speeds, and produce lower eddy current losses [7]. At
present, among
sleeves among the
and canthe high-speed
withstand permanent
higher magnet
speeds,magnet
and producemotors with a composite material
present, high-speed permanent motorslower
with aeddy current
composite losses sleeve
material [7]. At
sleeve successfully
present, among prepared
the at home
high-speed and abroad,
permanent the highest
magnet motors power
with is composite
a the 8 MW surface
material
successfully prepared at home and abroad, the highest power is the 8 MW surface mounted
mounted
high-speedhigh-speed
sleeve successfully
permanent permanent
prepared magnet
magnetatmotor motor
homedeveloped
and developed
abroad,
in the in theStates
the highest
United United
power is States
[8],the [8],
8 MW
which which
surface
is used to
mounted high-speed permanent magnet motor developed in the United
match with the gas turbine and has a rated speed of 15 kr/min. The maximum speed States [8], whichis
Energies 2022, 15, x FOR PEER REVIEW 3 of 23

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is used to match with the gas turbine and has a rated speed of 15 kr/min. The maximum
speed
isthe
used
istothe rotor
match
developed
withinthe gas
in the Netherlands
turbine andfor
has a rated
for the micro-milling
speed of spindle
15 kr/min.
spindle [9], with a
rotor developed the Netherlands the micro-milling [9], The
withmaximum
a speed of
speed
speed of up to 200 kr/min. Figure 3 shows the power-speed distribution of awith
motor
a with a
up to is
200thekr/min.
rotor developed in the the
Figure 3 shows Netherlands for the
power-speed micro-milling
distribution spindle
of a motor [9],
with a carbon
carbon
speed offiber
up tosleeve.
fiber sleeve. 200 kr/min. Figure 3 shows the power-speed distribution of a motor with a
carbon fiber sleeve.

Figure 3. Rotor power-speed distribution of motor with carbon fiber sleeve.

Rotor power-speed
Figure3.3.Rotor
Figure power-speed distribution
distributionof motor withwith
of motor carbon fiber fiber
carbon sleeve.
sleeve.
With
Withthe thewide
wideapplication
applicationofoffiber-reinforced
fiber-reinforcedcomposite
compositesleeves
sleevesininsurface-mounted
surface-mounted
With
permanent the
permanentmagnet wide application
magnetmotors,
motors, thethe of
researchfiber-reinforced
research and development
and composite
development sleeves in surface-mounted
of high-performance
of high-performance fiber-re-
fiber-
permanent
inforced
reinforced magnetsleeves
composite
composite motors,
sleeves the
have research
gradually
have graduallyanddeepened,
development
deepened, and and of high-performance
the development
the developmentgoal goal fiber-re-
of re-of
inforced
search into
research composite
its its
into stress issleeves
stress mainly have
is mainly gradually
“accurate
“accurate stress deepened,
design”,
stress design”, and the
“efficient development
prestressing
“efficient goal of re-
prepara-
prestressing prepa-
tion”,
search and
ration”,into “high-reliability
and its“high-reliability use”use”
stress is mainly to“accurate
comprehensively improve
stress design”,
to comprehensively the
improve power
“efficient density
the power and sta-
prestressing
density prepara-
and
bility
tion”, of
stabilitythe
and motor system.
of“high-reliability
the motor system. use”The above-mentioned
The above-mentioned
to comprehensivelydevelopment
development
improvegoals
goals include
theinclude three
powerthree levels
levels
density and sta-
ofofmeaning:
meaning: first,
first,the
theinfluence
influence factors
factors such
such as
as motor
motor structure
structure
bility of the motor system. The above-mentioned development goals include three levels and
and service
service conditions
conditions are
are
combined, the sleeve
ofcombined,
meaning: the
first, theprestress
sleeve influence field and
field andstress
factors stressconcentration
such as concentrationphenomenon
motor structure phenomenonare are
and service compre-
comprehen-
conditions are
hensively considered,
sively considered, andand the sleeve
the sleeve stressstress field
field is is accurately
accurately and efficiently
and efficiently designed;
designed; next the
combined, the sleeve prestress field and stress concentration phenomenon are compre-
next theissleeve
sleeve prepared is prepared
with high with high efficiency
efficiency and lowand low damage;
damage; finally, finally,
the highthe high reliabil-
reliability of the
hensively
sleeve
ity is sleeve
of the
considered,
guaranteed and the
through
is guaranteed the sleeve stress
three-level
through testfield ismaterial,
of thetest
the three-level
accuratelysleeve
of the material,
and efficiently
sample,
sleeve and
designed;
rotor
sample,
next
and the sleeve
prototype.
rotor Figure
prototype. is prepared
4 shows
Figurethe4with
mainhigh
shows the efficiency
research
maincontent and
research low damage;
of content
stress design and
of stress finally, the high
manufacturing
design and man-ofreliabil-
ity of the
compositeof
ufacturing sleeve
sleeves. is guaranteed
composite sleeves. through the three-level test of the material, sleeve sample,
and rotor prototype. Figure 4 shows the main research content of stress design and man-
ufacturing of composite sleeves.

Figure 4. Main research contents of stress design and manufacture of the composite material sleeve.
Energies 2022, 15, 2467 4 of 22

In order to achieve the goals of “accurate stress design”, “efficient prestress prepa-
ration” and “high-reliability use” of composite sleeves, this paper summarizes four key
technologies involved in the design and preparation of high prestressed composite sleeves,
as follows:
(1) Material research to match the requirements of high-speed, high-power density
motors is the basis for sleeve research and application. The use of high-strength, low-
density composite materials to prepare the sleeve can effectively reduce the thickness
of the sleeve structure, improve the pre-tightening effect of the sleeve, and improve the
motor efficiency and power density. To meet the sleeve requirements of high strength and
a high preloading effect, it is necessary to comprehensively consider factors such as the
actual working conditions of the rotor and the cost of the rotor and select an appropriate
material system.
(2) Reasonable stress design is key to ensuring the safe and stable operation of the rotor.
The sleeve stress is directly related to the rotor’s structural integrity and service safety.
The minimum sleeve stress should meet the prestress required for the rotor structural
integrity, and the sleeve stress concentration caused by the structure and the sleeve stress
increment caused by the rotor service conditions should also be considered, to ensure that
the maximum stress of the sleeve is always less than the allowable strength of the material.
(3) The preparation method with high efficiency and low damage has difficulty re-
alizing the application of sleeve engineering. The two-step prestressing manufacturing
method of winding first and then press-fitting has the disadvantages of a complicated
preparation process and easy damage to the rotor. The one-step prestressing manufacturing
technology of large tension winding with low damage and high preloading effect has
obvious advantages.
(4) Test characterization is key to ensuring sleeve quality and safety in use; the experi-
mental test is the most basic and direct method to evaluate the stress design and preparation
quality of the composite sleeve.

2. Application of Sleeve Composite Materials

With the development of high-performance fiber-reinforced composite materials, a
variety of materials are available for the application of high prestressed sleeves. The
main normal temperature properties of common sleeve materials are shown in Table 1. It
can be seen that fiber-reinforced composites have the characteristics of low density, high
strength, and high resistivity [7]. The surface linear velocity of the high-power, high-speed
motor rotor is high, the strength of non-magnetic metal cannot meet the requirements, and
with metal as a conductor, the eddy current loss is large. When the linear velocity of the
outer surface of the rotor is higher than 150 m/s, the strength of the glass fiber composite
material cannot meet the demands of the rotor [10]. Carbon fiber composite material is the
most common sleeve composite material with high strength and low high-frequency eddy
current loss and is suitable for high-power permanent magnet motors [11]. For the rotor
with an outer edge linear velocity of more than 250 m/s, carbon fiber is the best choice
for the sleeve material [9]. Zhang F et al. [12] determined the sleeve of the motor with the
same speed and power by design and compared the non-magnetic alloy, semi-permeable
alloy, and carbon fiber composite sleeve under different working conditions of static, cold
rotation, and hot rotation. The stress distribution characteristics and design laws of the
three material sleeves are summarized. It is found that: (1) the stress response of alloy
sleeve decreases with the increase in rotor temperature, while the carbon fiber sleeve does
not change much; (2) for rotors with a high surface speed, the thickness of the carbon fiber
sleeve is much smaller than that of the alloy sleeve; (3) the rotor eddy current loss of the
carbon fiber sleeve is much smaller than that of alloy sleeve; (4) the temperature rise in the
carbon fiber sleeved motor is much smaller than that of the alloy sleeved motor. Although
the thermal conductivity of carbon fiber is poor, the eddy current loss of the carbon fiber
sleeve is low, resulting in a small temperature rise.
Energies 2022, 15, 2467 5 of 22

Table 1. Main material properties of the rotor sleeve.

Inconel718 B20AT1200 Glass Fibre Carbon Fiber

Density, ρ/(g·cm−3 ) 8.20 7.60 2.54 1.76
Tensile strength, 3447 3750
1030 435
σt,max /MPa (Parallel to the fiber) (Parallel to the fiber)
Thermal conductivity, 1.0 5.0
11.4 30.0
k(W/m·K) (Parallel to the fiber) (Parallel to the fiber)
4.00 × 1012 1.50 × 10−5
Resistivity, ρt /Ω·m 1.25 × 10−6 5.90 × 10−7
(Parallel to the fiber) (Parallel to the fiber)

At present, the sleeve is a mostly thermosetting composite material. Thermosetting

resin has poor toughness, a long curing cycle, low production efficiency, and the prestress
relaxation caused by curing, resin flow, and other factors in the molding process is obvious,
while the pre-tightening effect is not good. To improve the pre-tightening effect of ther-
mosetting composites, resin modification can be used to increase the curing rate, reduce
the curing temperature, and reduce the stress relaxation caused by resin flow and mold
expansion. Liu [13] developed thermosetting resin for efficient wet winding, which has a
low curing temperature and short application period and can achieve rapid curing. The
influence of resin curing heat is small, which is conducive to improving the pre-tightening
effect and high forming efficiency.
In recent years, high-performance thermoplastic composites have shown great per-
formance advantages in industrial applications due to their advantages of high damage
tolerance, high service temperature, short processing cycle, environmental protection, and
recycling [14]. The resin matrix of thermoplastic composite prepreg is polymerized polymer.
The resin has good load transfer characteristics, can withstand higher forming prestress,
and can be consolidated in situ. The forming efficiency is high, the stress “freezing” is
realized, the stress relaxation is small, and the demand for a high pre-tightening sleeve
is matched. High-prestressed molding has a very low tolerance for raw material damage.
Most of the existing imported or domestic thermoplastic prepreg materials need to be used
after cutting, which inevitably causes fiber damage and material waste in the process of
cutting. Chen et al. [15] developed a narrow-band preparation platform, which can avoid
fiber damage caused by slitting. In the follow-up, it is necessary to further study the mech-
anism and composite mechanism of high-performance thermoplastic resin impregnation
carbon fiber and optimize the process to achieve low-cost and high-efficiency preparation
of a high-prestressed special narrow-band prepreg sleeve.
Due to the poor thermal conductivity of fiber-reinforced composite materials, some
scholars have compared the loss and heat generation of rotors sleeved with different
materials. Zhang F et al. [12] compared the rotor loss of non-magnetic alloy, fiber composite,
and semi-permeable alloy sleeved rotors and found that the eddy current loss of fiber
composite material was the smallest at no-load and under load and was smaller than that
of the alloy sleeve by about an order of magnitude. Under the same cooling conditions,
the rotor temperature rise of the fiber composite material is also the smallest. In order to
ensure the safe and stable operation of the rotor system and meet the requirements of the
rotor life, many researchers have studied the rotor thermal field and designed a cooling
system for the rotor. By designing a reasonable cooling system, the rotor temperature
can be controlled to meet the material and structural requirements [16]. The research on
rotor eddy current loss and thermal field is relatively mature, and the cooling methods
are also more diverse. This paper mainly focuses on the stress design and prestressing
manufacturing content of the rotor sleeve. The rotor loss, thermal field, and cooling issues
are indeed issues to be considered in rotor design, but this is not the focus of this article, so
it will not be discussed extensively.
Suitable composite material is the basis of the research of high-performance motor
sleeves. At present, sleeve composite materials are still in the development stage. In
order to meet the requirements of advanced motors with high speed and high power
Energies 2022, 15, 2467 6 of 22

density, it is urgent to develop a material system with high efficiency, low cost, and a high
pre-tightening effect.

3. Stress Design of the High Prestressed Composite Sleeve

In the case of selecting the sleeve material, a reasonable sleeve stress design is key
to ensuring the safe and stable operation of the rotor. The stress design of the composite
material sleeve is mainly composed of a prestressing design and stress concentration calcu-
lation, which affects the structural integrity of the rotor during operation and determines
the safety of the composite material sleeve and rotor [17].

3.1. Design Principle of Sleeve Stress

Sleeve stress design is a multi-boundary condition comprehensive design; existing
researchers mainly consider the material strength, the structural integrity of the sleeve,
rotor electromagnetism, heat dissipation, and other factors.
When the sleeve material is selected, the maximum stress of the sleeve must be less
than the allowable strength of the material [12,18–21]. The design of sleeve stress should
not only consider the allowable strength of the material but also ensure that all parts
of the rotor do not separate at any temperature or speed [9,10,16,22–25]. The magnetic
steel is not usually separated from the mandrel [9,10,24,25], and the magnetic steel is not
separated from the sleeve [16]. Fang et al. [24] believed that for the surface attached rotor,
the magnetic steel and the sleeve would always be in contact under the action of centrifugal
load, so it was only necessary to ensure contact between the magnetic steel and the mandrel.
Therefore, the key to the sleeve stress design is to ensure that at all operating speeds and
temperatures, there is no separation between the magnetic steel and the mandrel, and the
maximum stress of the sleeve does not exceed the allowable value of the material. The
stress conditions for the rotor sleeve of a surface-mounted high-speed permanent magnet
motor are as follows [25].

Re f [σs,m (r )] < σlim it , σc < 0
, (1)
0 ≤ r ≤ Rso, 0 ≤ Ω ≤ Ωmax , Tmin ≤ T ≤ Tmax

where σs,m is the tangential stresses of the sleeve and the magnetic steel, σc is the contact
pressure between the magnetic steel and the core shaft, Ω is the speed, Ωmax is the maxi-
mum speed, Tmin and Tmax are the lowest and highest possible temperatures of the rotor.
The above formula points out the conditions to be met in the design of sleeve stress but
does not quantify the sleeve stress. Zhou et al. [26] quantitatively calculated the minimum
pre-pressure required by the sleeve by calculating the centrifugal force of the magnetic steel
on the condition that the precompression stress produced by the sleeve on the magnetic
steel is not less than the centrifugal force of the magnetic steel.
In addition, other functional conditions of the rotor need to be considered. When the
compressive stress provided by the sleeve to the magnetic steel is constant, the greater
the thickness of the sleeve, the smaller the stress of the sleeve, and the greater the safety
margin of the sleeve [25,27]. However, the increase in sleeve thickness will increase the
gap between the magnetic steel and the stator, resulting in a decrease in magnetic flux
density [25] and a reduction in motor efficiency. The composite material is a bad conductor
of heat, the thickening of the sleeve is not conducive to the cooling of the rotor, and the
high temperature of the rotor leads to a loss of magnetic steel. When designing the sleeve,
factors such as the sleeve stress, motor electromagnetic condition, and rotor heat dissipation
should be considered comprehensively. Damiano et al. [23] comprehensively considered
electromagnetic, mechanical, and other design factors, and proposed to take the minimum
volume as the design goal of the sleeve. Shen et al. [21] took minimization of sleeve
thickness as the main objective of the sleeve design.
Energies 2022, 15, 2467 7 of 22

Mises equivalent stress was used to evaluate the stress level of composite materials
by some researchers [9,23,28,29]. Mises stress was usually used to characterize isotropic
materials and was not suitable for composite materials. do Nascimento et al. [29] pointed
out that the Mises stress was only used to evaluate the results of the stress analysis and
could not be used as a failure criterion for composite sleeving because it was valid only for
isotropic materials. Zheng et al. [30] used the Cai–Hu failure criterion to judge the failure
of the composite material sleeve. Wang et al. [25] used the Tresca criterion to judge the
failure of the composite material sleeve.
In a word, the existing research considers the design principle of material strength
and rotor structural integrity but fails to provide the optimal value and design basis for
comprehensively considering the strength, stress, electromagnetic, heat dissipation, and
other related parameters of the sleeve material, and lacks the quantitative optimization
calculation principle.

3.2. Calculation Method of Sleeve Stress

At present, the analytical method and finite element method are used to analyze the
stress of composite sleeves. The analytical method is suitable for the preliminary design of
the rotor sleeve because of its advantages of small computation and high efficiency [18]. The
finite element method is often used to analyze the stress of the sleeve and the non-uniform
temperature field of the sleeve in complex rotor structures.

3.2.1. Analytic Method

By simplifying the motor rotor to a multilayer two-dimensional disc, an analytical
model is established, based on the theory of elastic mechanics and material constitutive
equation, space rotation circle of stress and displacement equation, combined with the
rotor interference between the surfaces in quantity, and according to the stress continuity
boundary conditions, by the known rotor size, amount of interference between the contact
surface, and the rotor speed. All the coefficients in the stress and displacement equations of
the rotor can be obtained, and then the sleeve stress [9,18,21,31–37] can be obtained, and
the stress field of the sleeve affected by temperature [21,31–36] can also be obtained by
taking into account the stress–strain relationship of the material during thermal expansion.
In actual design and manufacturing, there may be an adhesive layer between the
rotor mandrel and the permanent magnet [18,34]. Liu et al. [34] established a rotor stress
distribution model with an adhesive layer. According to the theory of elasticity and
thermodynamics, the analytical solution of the radial displacement of the inner and outer
surface of the rubber layer and the stress of the sleeve are obtained.
By analyzing the influence of rotation speed and temperature changes on the inter-
ference amount, the static pressure and working pressure between the sleeve and perma-
nent magnet can be calculated according to the interference amount to obtain the sleeve
stress [38,39].
In recent years, researchers [10,17,26,28,39–41] have adopted a prestressed forming
method that is more suitable for the sleeve of fiber composite materials, namely the high-
tension torsional winding method, also known as the carbon fiber binding method. Figure 5
shows the section of the motor sleeve for winding molding. Compared with the traditional
winding method, by selecting appropriate winding material, improving winding equip-
ment, and optimizing the winding process, the winding tension of fiber composite material
is greatly improved, and the pre-pressure of the permanent magnet is provided while the
sleeve is prepared, and damage to the complex process and parts caused by interference
assembly is avoided.
 5 shows the section of the motor sleeve for winding molding. Compared with the tradi-
tional winding method, by selecting appropriate winding material, improving winding
equipment, and optimizing the winding process, the winding tension of fiber composite
material is greatly improved, and the pre-pressure of the permanent magnet is provided
Energies 2022, 15, 2467 while the sleeve is prepared, and damage to the complex process and parts caused by 8 of 22
interference assembly is avoided.

Figure 5. Multi-layer winding of composite sleeve. Reproduced from [41], Compos. Struct.: 2018.
Figure 5. Multi-layer winding of composite sleeve. Reproduced from [41], Compos. Struct.: 2018.
Binder et al. [10] proposed that if the composite sleeve is regarded as a thin shell
structure,etFormula
Binder al. [10] (2)
proposed
can be used that if to the composite
calculate sleeve is
the pressure regarded
caused by the aswinding
a thin shell
tension.
structure, Formula (2) can be used to calculate the pressure caused
If the sleeve is regarded as a thick shell structure, Formula (3) is used to calculate by the winding tension. the
If the sleeve generated
pressure is regarded byasthea winding
thick shell structure, Formula (3) is used to calculate the
tension.
pressure generated by the winding tension.
σt,prestress · hb
pc,prestress σ =t , prestress ⋅ hb , (2)
pc , prestress = rb , (2)
rb
−1
ri 2 r a−21
 
pc,prestress (r ) = σt,prestress ·
r r2 − r 2 r  r2
2 1+2 , (3)
pc , prestress ( r ) = σ t , prestress ⋅  2ai 2 i 1 + a2   , (3)
where, pc,prestress is the pressure generated by winding, ra − ri  σt,prestress
r   is the winding tension, hb
and rb are the thickness and radius of the composite layer, respectively, ri and ra are the
where, pc,prestress is the pressure generated by winding, σt,prestress is the winding tension, hb and
inner and outer radius of the winding layer, respectively.
rb are the thickness and radius of the composite layer, respectively, ri and ra are the inner
Zu et al. [17,40–42] considered stress-elastic relaxation after multi-layer winding. Based
and outer radius of the winding layer, respectively.
on the static equilibrium equation of the ring and the anisotropic material constitutive
Zu et al. [17,40–42] considered stress-elastic relaxation after multi-layer winding.
equation, the radial and annular stress equations of the composite material were obtained.
Based on the static equilibrium equation of the ring and the anisotropic material constitu-
The annular stress of the winding layer was obtained by combining the stress of the winding
tive equation, the radial and annular stress equations of the composite material were ob-
layer and the boundary conditions of the inner and outer layers. The annular stress of the
tained. The annular stress of the winding layer was obtained by combining the stress of
inner layer after the n-th winding layer was calculated by the elastic superposition effect,
the winding
and then layer and the
the sleeve boundary
stress was obtained.conditions of the inner and outer layers. The annular
stress of The
the inner layer after the
method of reducing the rotor n-th winding layer was calculated
to a two-dimensional diskby canthe elastic
simply super-
and directly
position effect, and then the sleeve stress was obtained.
calculate the sleeve stress of the integral magnetic steel rotor but cannot calculate the sleeve
The method
stress of reducing
of the partitioned the rotor
magnetic to arotor.
steel two-dimensional
The method of disk can simply
calculating theand directly
sleeve stress by
calculate the sleeve stress of the integral magnetic steel
the known interference and winding tension can obtain the sleeve stress, but it can rotor but cannot calculate theonly
sleeve stress of the partitioned magnetic steel rotor. The method
be used to check the sleeve stress under the known sleeve stress boundary condition and of calculating the sleeve
stress by the
cannot known
realize theinterference
stress design andforwinding
the rotortension
sleeve. can obtain the sleeve stress, but it
can onlyFor be used
the block magnetic steel structure, thethe
to check the sleeve stress under known sleeve
compressive stress stress
of theboundary con- by
sleeve caused
dition and cannot realize the stress design for the rotor sleeve.
the centrifugal action of the magnetic steel during the high-speed rotation of the rotor can
be calculated [26,28,43]. Zhou Y et al. [26] believed that the stress and strain of partitioned
magnetic steel generated by the centrifugal load was different from that of the overall
annular magnetic steel. Due to the continuous material structure of the overall annular
magnetic steel, there was stress between the elements of the magnetic steel, while there was
no stress between each block of the partitioned magnetic steel. Therefore, the centrifugal
load of each piece of magnetic steel acts directly on the inner surface of the sleeve. The
Energies 2022, 15, 2467 9 of 22

centrifugal load of block magnetic steel generates pressure on the inner surface of the
sleeve [28].
ρm R2mo − R2mi ω 2 ( Rmo + Rmi )


Pw = , (4)
4Rmo
where ρm refers to the density of magnetic steel, Rmo, and Rmi , respectively, refer to the
outer radius and inner radius of magnetic steel, ω refers to the rotor speed.
Do Nascimento et al. [29] comprehensively considered the centrifugal load of the
sleeve, magnetic steel centrifugal load, and interference fit to calculate the stress of the
rotor sleeve.
To sum up, the method of calculating the sleeve stress with known interference and
winding tension can only be used to calculate the stress after known boundary conditions
and loading of the sleeve. If the sleeve stress needs to be designed, other boundary
conditions need to be added. The design of the sleeve stress can be quantified by the
centrifugal load calculation of magnetic steel. The analytical method can design and
calculate the prestress of the sleeve according to the simplified rotor condition, but the real
rotor structure is complicated and there is stress concentration, so the analytical method
cannot accurately solve the problem.

3.2.2. Finite Element Method

The block magnetic steel structure is complex, the fiber-reinforced composite material
has anisotropy, the rotor service speed is very high, the experimental conditions are harsh,
and the analytical method is difficult to calculate. By using finite element analysis, the
precise and detailed stress distribution of the sleeve can be obtained, which can be used as
a continuation and supplement of experimental research, and the influencing factors of the
sleeve stress can be analyzed and discussed.
Borisavljevic et al. [9] used the ANSYS software for finite element modeling and
analysis, and the PLANE82 element for 2D structural modeling. Researchers [17,41] used
the ABAQUS finite element simulation software to establish a rotor finite element model
and used the equivalent temperature field method to simulate winding tension, that is,
assigning a thermal expansion coefficient and temperature field to the winding layer, using
virtual thermal stress to simulate fiber stress generated by winding tension, and establishing
a contact element between layers to simulate relaxation of the winding layer. Zu et al. [41]
established a quarter model and set symmetric constraints on the symmetry plane of the
model in order to improve the computational efficiency. Zhou et al. [17] simulated the
layer-by-layer winding process by using the Model Change function of the ABAQUS finite
element simulation software.
Most studies show that the computational results of the analytical method and finite
element method are similar [9,17,22,29,34,35,41,44]. However, Chen et al. [45] found that
because the edge effect of permanent magnet and magnetic pole filling was considered in
the finite element model, there would be a certain error between the analytical solution and
the finite element results. Wang [28] believed that, if the laminated structure of composite
materials was not considered in the finite element modeling, the analytical solution of
tangential stress of the sleeve under rotation would have a large deviation from the finite
element solution. do Nascimento et al. [29] found that the computational resources used by
the analytic method were much smaller than those used by the finite element method.
For most sleeves, the thickness is thin and the structure is relatively simple. When the
calculated rotor can be simplified as a two-dimensional disk, the radial and circumferential
stresses at any position inside the sleeve can be obtained by the analytical method. In this
way, a relatively accurate stress value can be quickly obtained for a rotor with a simple
structure, and the calculation efficiency is high. However, if the axial difference or the
segmented magnetic steel structure is considered, the finite element method needs to be
used to calculate the rotor stress value. Such rotor stress calculation is more in line with the
actual stress distribution, but the amount of calculation is large. The sleeve designer can
Energies 2022, 15, 2467 10 of 22

choose an appropriate calculation method according to the boundary conditions for the
calculation of the sleeve stress and the requirements of the calculation results.

3.3. Influence Factors and Rules of Sleeve Stress

Composite material has a strong integration of design and manufacturing charac-
teristics, analysis of sleeve stress influence factors, and reasonable design of rotor sleeve
and rotor structure, can reduce the stress concentration of the sleeve, and can effectively
improve the safety of the sleeve. In recent years, through the analytic method and finite
element method, scholars have mainly studied the influence factors of the prestress field
and stress concentration.

3.3.1. Factors Affecting Prestress Field of Sleeve

In order to ensure the integrity of the rotor structure, the sleeve is formed by inter-
ference assembly and tension winding to form a certain amount of prestressing, and the
prestress is used to restrain the centrifugal action of the rotor at high speed.
The prestress of the sleeve is formed by interference assembly. With the increase
in interference, the greater the circumferential stress of the sleeve, the greater the radial
pressure of the sleeve on a permanent magnet. When the compressive stress required by the
permanent magnet is constant, the greater the interference, the greater the annular tensile
stress of the sleeve, and the smaller the thickness of the sleeve required, but it should be
ensured that the sleeve stress is less than the allowable stress of the material. When the
linear velocity of the outer surface of the rotor is constant, the thickness and interference
of the sleeve decrease proportionally with the decrease in the outer diameter of the rotor.
When the outer diameter and speed of the rotor are constant, the interference amount of
the sleeve depends on the maximum annular tension stress of the sleeve. The larger the
annular tension stress is designed, the larger the interference amount will be [18].
In recent years, prestress of the sleeve formed by tension winding has been widely
explored. Zu et al. [17,40,41] analyzed the stress distribution of a sleeve prepared by three
tension winding systems of equal tension, equal torque, and taper tension, and obtained
the tension winding system of equal residual stress distribution by an iterative method. It
is found that the sleeve thickness of an equal tension winding system is the smallest, the
sleeve thickness of the conical tension winding system and equal residual stress distribution
is relatively thicker, and the sleeve thickness of equal torque distribution is the thickest.
Equal tension winding is more suitable for a rotor with a thin carbon fiber sleeve, while an
equal stress distribution is more suitable for a rotor with a thick sleeve. Figure 6 shows the
radial compressive stress of permanent magnets under different winding tensions.
Through the analysis of the tension system, molding process, material, and other
influencing factors in the tension winding, the relationship between the winding tension
and residual tension is obtained in the existing research, and the stress field required by
the design of the winding tension is obtained. Springer et al. [46–48] assumed that the
continuous winding of fiber bundles was simplified to the external pressure superposition
of thin-walled cylinders of multilayer composite materials. Considering the winding and
curing process, five submodels were established, including thermochemistry, fiber motion,
stress–strain, pore diffusion, and strength assessment. Zhao et al. [49,50] numerically
simulated the fiber wet winding process by using the finite element method, and analyzed
the temperature, curing degree, resin viscosity, permeability, residual stress, and fiber
content in the winding and curing process, and the fiber content measured in the experiment
was consistent with the calculated value. Xing et al. [51,52] studied the relationship between
toroidal winding tension and residual tension of rigid cylindrical cylinders and deformable
thick-walled cylinders, as well as the differential equation of residual tension distribution
after winding determined by a given winding tension. Shi et al. [53,54] established an
analytical algorithm for the relationship between residual tension and winding tension
by using the principle of stress superposition within the elastic range based on the elastic
deformation of the anisotropic winding layer and the theory of isotropic thick-walled tube
 Energies 2022, 15, 2467 11 of 22

lining. Wu et al. [55] proposed an optimal design method for the tension of a fiber wound
thick-walled pipe and established a model and method to calculate the change of residual
Energies 2022, 15, x FOR PEER REVIEW 11 of 23
internal stress of composite pipe caused by winding tension. Chen et al. [56] studied the
influence of the resin curing mode and period on the prestressing of composites.

6. The
Figure 6.
Figure The radial
radialcompressive
compressivestress of permanent
stress magnets
of permanent under
magnets different
under winding
different systems.
winding systems .
Reproduced from [41], Compos. Struct.: 2018.
Reproduced from [41], Compos. Struct.: 2018.
In the process of rotor service, the stress of the sleeve will increase obviously due to
Throughofthe
the influence analysisload
centrifugal of the
andtension system, molding
rotor temperature rise. As theprocess,
carbonmaterial, and other in-
fiber composite
fluencing
material has factors in the
a negative tension
coefficient of winding,
expansion,the relationship
but the mandrel and between
magneticthe winding
steel material tension
and residual
in the tension
sleeve both have is obtained
a positive in the existing
coefficient research,
of expansion, and thestress
the tangential stressoffield required by
the sleeve
the design
increases of the winding
significantly with the tension
increaseisinobtained. Springerand
rotor temperature, et al.
the [46–48]
maximum assumed
speed ofthat the
non-separation
continuous between
winding magnetic
of fiber steelwas
bundles and simplified
mandrel increases with the pressure
to the external increase in rotor
superposition
temperature [9]. Du et al. [16] pointed out that the stress of the rotor
of thin-walled cylinders of multilayer composite materials. Considering the winding and after the temperature
rise can easily reach the allowable strength of the material, and the stress of the rotor at
curing process, five submodels were established, including thermochemistry, fiber mo-
high temperatures must be accurately calculated.
tion, stress–strain, pore diffusion, and strength assessment. Zhao et al. [49,50] numerically
The non-uniform temperature field of the rotor has little influence on the stress of
simulated the fiber wet
the sleeve [32,57,58]. Du etwinding process
al. [58] found bythe
that using the finite
influence of theelement method,
temperature and analyzed
difference
the temperature,
between the sleeve curing degree,magnet
and permanent resin viscosity,
on the sleeve permeability,
stress was almostresidual stress,and
negligible, and fiber
content
the temperature difference between the rotor core and the permanent magnet had little experi-
in the winding and curing process, and the fiber content measured in the
ment wason
influence consistent
the stresswith
of thethe calculated
sleeve. The rotor value.
stressXing et al.by
obtained [51,52] studied the
the isothermal modelrelationship
is
slightly larger
between thanwinding
toroidal that obtained by the
tension and temperature-stress
residual tensioncoupled of rigid model.
cylindrical cylinders and
During thick-walled
deformable the rotor operation, the tangential
cylinders, as well as stress
the of the sleeve increases
differential equationslightly with tension
of residual
the increase in rotational speed. Wang et al. [25] pointed out that, with the increase in rotor
distribution after winding determined by a given winding tension. Shi et al. [53,54] estab-
speed, the stress concentration in the inner wall of the sleeve caused by a magnetic steel
lished an analytical algorithm for the relationship between residual tension and winding
block would be intensified. Given the stress changes of the sleeve in the three states of
tension
static noby using the principle
temperature of stress
rise, no rotation superposition
temperature rise, andwithin the elastic
rotation range based on the
with a temperature
elastic deformation of the anisotropic winding layer and the
rise, the study found that the maximum stress of the sleeve is in a state of rotation theory of isotropic
with a thick-
walled tube rise
temperature lining. Wu et al. [55] proposed an optimal design method for the tension of a
[11,24].
fiber wound thick-walled pipe and established a model and method to calculate the
3.3.2. Influence
change Factors
of residual of Sleeve
internal Stress
stress of Concentration
composite pipe caused by winding tension. Chen et
al. [56] studied the influence of thethe
The magnetic steel structure of surface-attached
resin curing mode rotor is mainly
and period on divided into
the prestressing of
integral
composites.type and block type, as shown in Figure 7 [58]. The integral permanent magnet has
the advantages of simple structure, easy processing, and high mechanical strength, but the
In the process of rotor service, the stress of the sleeve will increase obviously due to
utilization rate of the permanent magnet material is low. The structure is shown in Figure 7a.
the influence
Block of centrifugal
permanent magnets areload andprocessed
usually rotor temperature rise.[5,18,59].
into tile types As the carbon fiber composite
Block magnetic
material has a negative coefficient of expansion, but the mandrel and magnetic steel ma-
terial in the sleeve both have a positive coefficient of expansion, the tangential stress of
the sleeve increases significantly with the increase in rotor temperature, and the maximum
speed of non-separation between magnetic steel and mandrel increases with the increase
 3.3.2. Influence Factors of Sleeve Stress Concentration
The magnetic steel structure of the surface-attached rotor is mainly divided into in-
tegral type and block type, as shown in Figure 7 [58]. The integral permanent magnet has
the advantages of simple structure, easy processing, and high mechanical strength, but
Energies 2022, 15, 2467 12 of 22
the utilization rate of the permanent magnet material is low. The structure is shown in
Figure 7a. Block permanent magnets are usually processed into tile types [5,18,59]. Block
magnetic steel is arranged in close rows on the outer circumference of the core shaft, as
steel is arranged
shown in close
in Figure rows
7b,c, on the
which canouter circumference
reduce of theloss
the eddy current coreofshaft, as shown in
the permanent magnet
Figure[24,25]
7b,c, which can reduce
and improve the eddy current
the utilization loss of the permanent
rate of permanent magnetThe
magnet materials. [24,25]
edgeandof block
improve the utilization
magnetic steel andrate
theof permanent
filling magnet materials.
place between The edge
magnetic poles of block
can easily magnetic
lead to the stress
steel and the filling place between magnetic poles can easily lead to the stress concentration
concentration of the sleeve. Existing studies have analyzed the influencing factors of stress
of theconcentration
sleeve. Existing studies
and reducedhave analyzed
the the influencing
stress concentration by factors of stress
optimizing concentration
the rotor structure.
and reduced the stress concentration by optimizing the rotor structure.

(a) (b)

(c)

FigureFigure 7. Block
7. Block permanent
permanent magnet
magnet rotorrotor structure:
structure: (a) the
(a) the integral
integral permanent
permanent magnet
magnet structure, (b)
structure,
the block ntegral permanent magnet structure, (c) the block permanent magnet structure
(b) the block ntegral permanent magnet structure, (c) the block permanent magnet structure with with pole
filler.
pole filler.

The densely packed segmented magnetic steel will not produce obvious stress con-
centration [22,36] but will produce bending stress at the pole gap of the sleeve, leading to
stress concentration [36]. The additional bending stress increases the maximum stress of
the sleeve, and even exceeds the stress limit of the sleeve. It is necessary to add materials
with a density similar to permanent magnets in the inter-pole air gap to reduce or eliminate
the bending stress [22].
However, in the above study, the clearance of magnetic steel blocks is very small.
Zhang et al. [33] analyzed the two situations when the distance between adjacent permanent
magnets was 1◦ and 5◦ and found that the edge effect caused by the partition of permanent
magnets would produce larger bending stress on the inner surface of the carbon fiber
sleeve, and the larger the distance between adjacent permanent magnets, the greater the
bending stress of the carbon fiber sleeve. Hao [38] quantitatively analyzed the influence
of pole spacing on sleeve stress by using the pole arc coefficient of the permanent magnet,
which refers to the ratio of the arc length of the permanent magnet to the pole distance. It
is found that the polar arc coefficient of the permanent magnet has little influence on the
maximum radial stress of the sleeve but has a great influence on the maximum tangential
stress of the sleeve. The maximum tangential stress increases first and then decreases with
an increase in the polar arc coefficient of a permanent magnet.
Energies 2022, 15, 2467 13 of 22

Wang et al. [25] found that when the segmented magnetic steel is in a state of com-
pressive stress, the rotor stress remains stable, and the number of blocks has no obvious
effect on stress. However, when the magnetic steel is under tensile stress, the tangential
stress of the sleeve decreases with the increase in the number of permanent magnets. The
analysis shows that the edge effect decreases with the increase in the number of magnetic
blocks. It is found that the stress concentration of the sleeve is its maximum at the minimum
operating temperature. In practice, the increase in the number of magnetic steel blocks will
increase the difficulty of manufacturing. The rotor stress, loss, and manufacturing difficulty
should be considered in the design.
The elastic modulus and thermal expansion coefficient of the filling between the poles
will directly affect the maximum stress of the rotor sleeve at static and dynamic conditions
as well as the temperature rise [18,36–38]. Hao [38] found in his study that whether or not
there is inter-pole filling has a great influence on the stress of the sleeve, and inter-pole
filling can effectively reduce the stress concentration of the sleeve. The effect of different
filling materials on the stress of the sleeve is compared. It is found that the material with a
large difference between the thermal expansion coefficient and that of magnetic steel as the
filling material leads to a great change in the radial stress and tangential stress of the sleeve
when the temperature changes. Wan et al. [18] found that in the case of the rotor without a
temperature rise, due to the difference of material density, elastic modulus, and Poisson’s
ratio, the annular tensile stress, radial compressive stress, and bending stress received by
the sleeve with a stainless steel inter-pole filling were the smallest, the distribution of radial
compressive stress was the most uniform, and the residual strength of the sleeve was the
highest. However, when the rotor temperature rises, the residual strength of the sleeve
decreases due to the thermal expansion of the material. The rotor using titanium alloy as
the magnetic pole spacing has low bending stress and high residual strength of the sleeve
in operation, with or without a temperature rise.
Du et al. [58] studied the influence of the gap between the magnetic pole filling and
the magnetic steel block on the stress of the sleeve and found that, in a certain range, with
the increase in the gap, the tangential maximum stress of the sleeve decreases slightly.
Chen et al. [5,45] analyzed the stress distribution of a quad pole rotor with inner
aluminum electrode filling under a static, non-temperature rise rotation, and temperature
rise rotation. It is found that the contact pressure between the inner surface of the carbon
fiber sleeve and the outer surface of the rotor core is approximately a square wave with a
period of 90◦ under three operating conditions.
Chen et al. [45] found that the inner wall of the sleeve is affected by the internal material
and structure, resulting in greater bending stress and stress concentration, especially in
the magnetic pole gap or filling part of the magnetic steel block. To slow down the
bending stress of the inner wall of the sleeve, scholars set thin glass fiber material or metal
material in the inner layer of the sleeve [9–11,17,22,32,36,37,60], as shown in Figure 8, which
can effectively slow down the stress concentration of the sleeve, significantly reduce the
maximum stress of the carbon fiber composite layer, and increase the reliability of the rotor,
and the inner metal material can also increase the overall stiffness of the sleeve [60].
Due to the influence of the rotor forming process, there may be a rubber layer between
the magnetic steel and the mandrels. Liu et al. [34] proposed a motor–rotor model based
on the integral magnetic steel structure with inter-shaft filling and found that under high-
speed and high-temperature conditions, the tangential stress of the sleeve of the rotor
with inter-shaft filling is slightly smaller than that of the rotor without inter-shaft filling.
There is little influence on the radial stress of the sleeve with or without inter axial filling.
Zheng et al. [30] found that for the segmented magnetic steel rotor, the rubber layer can
withstand a certain magnetic steel centrifugal force, which can reduce the stress of the
sleeve and improve the safety of the sleeve.
 bending stress of the inner wall of the sleeve, scholars set thin glass fiber material or metal
material in the inner layer of the sleeve [9–11,17,22,32,36,37,60], as shown in Figure 8,
which can effectively slow down the stress concentration of the sleeve, significantly re-
duce the maximum stress of the carbon fiber composite layer, and increase the reliability
of the rotor, and the inner metal material can also increase the overall stiffness of the sleeve
Energies 2022, 15, 2467 14 of 22
[60].

(a) (b)
Figure 8. Mixed sleeve construction: (a) thin glass fiber material in the inner layer of the sleeve; (b)
Figure 8. Mixed sleeve construction: (a) thin glass fiber material in the inner layer of the sleeve;
thin metal material in the inner layer of the sleeve.
(b) thin metal material in the inner layer of the sleeve.

Due to the influence

The efficiency of the rotor
of the current rotordesign
forming process,
method is lowthere may be
because therea rubber
are many layer be-
factors
tween the magnetic steel and the mandrels. Liu et al. [34] proposed
affecting the stress of the sleeve. In the follow-up research, artificial intelligence algorithms a motor–rotor model
based on the
and finite integral
element magnetic
analysis steel structure
technology can bewith inter-shaft
combined filling
to nest theandfinitefound that model
element under
high-speed and high-temperature
in the intelligent algorithm. After conditions, the tangential
several iterations, stress of and
the analysis the sleeve
designofofthe ro-
high-
tor with inter-shaft filling is slightly smaller than that of the rotor
prestressed fields can be studied to further exert the use efficiency of materials and reduce without inter-shaft fill-
ing. There is little
the application influence
threshold on the
of the radial stress
composite of the
material sleeve with or without inter axial
sleeve.
filling. Zheng et al. [30] found that for the segmented magnetic steel rotor, the rubber layer
4. Preparation
can withstand aof High magnetic
certain Prestressed steelComposite
centrifugal Sleeve
force, which can reduce the stress of the
sleeveWith
andthe improve the safety
development of of the sleeve.
science and technology, the speed of the high-speed perma-
nent The efficiency
magnet motor of is the current
higher, rotor designcentrifugal
the high-speed method isload low caused
becausebythere are many
a structure fac-
caused
tors affecting the stress of the sleeve. In the follow-up research, artificial
by the radial tensile stress increases, and the specific technology introducing suitable radial intelligence algo-
rithms and finite
compressive element
stress analysis
in advance, technology
namely can be combined
prestressing, pushes thetostructure
nest the stress
finite element
“origin”
model
forward in to
the intelligent
offset some or algorithm.
all of theAfter severalrotation
high-speed iterations, the radial
of the analysis and stress.
tensile design To of
high-prestressed
protect the permanent fields magnet
can be studied to further
from damage exerthigh-speed
during the use efficiency
rotationofand materials
ensureand the
reduce
integrity theofapplication threshold
the rotor structure andof non-separation,
the composite material sleeve.
this special technology is prestressed
manufacturing technology.
4. Preparation
There are of High
two kinds Prestressed
of prestress Composite Sleeve technology for the composite ma-
manufacturing
terialWith
sleeve,thewhich can be divided
development of science intoandtwo-step prestress
technology, manufacturing
the speed and one-step
of the high-speed per-
prestressmagnet
manent manufacturing.
motor is The higher,traditional winding centrifugal
the high-speed tension of a load smaller radial
caused byinternal pres-
a structure
sure is by
caused small, not enough
the radial tensiletostress
ensure that theand
increases, operation
the specific process of the rotor
technology magnet suit-
introducing steel
and spindle are not isolated; the winding sleeve assembly on
able radial compressive stress in advance, namely prestressing, pushes the structure stress the magnetic steel surface
is needed,
“origin” whichtocan
forward be some
offset madeor forallmagnetic steel preloading
of the high-speed rotation afterof thethe firsttensile
radial winding in-
stress.
terference assembly for two-step preparation of the prestressing
To protect the permanent magnet from damage during high-speed rotation and ensure sleeve. In recent years,
researchers
the integrity[10,17,26,28,39–41]
of the rotor structure have and adopted the high-tension
non-separation, winding
this special forming method
technology is pre-
known as the one-step method
stressed manufacturing technology. to prepare prestressed sleeves, which provides pressure for
magnetic steel through the winding tension while the sleeve
There are two kinds of prestress manufacturing technology for the composite mate- is winding.
rial sleeve, which can be divided into two-step prestress manufacturing and one-step pre-
4.1. Preparation of Prestressed Sleeve by the Two-Step Method
stress manufacturing. The traditional winding tension of a smaller radial internal pressure
The not
is small, traditional
enoughtension-wound
to ensure thatsleeve producesprocess
the operation less pressure
of theon the magnet
rotor inner layer, which
steel and
has difficulty meeting the design requirements of high-performance rotors. In order to
make the sleeve produce enough pre-tightening pressure on the magnetic steel, interference
assembly of the sleeve is required on the surface of the magnetic steel [18], and the two-
step method is adopted to prepare the prestressed sleeve. At present, there are two main
interference assembly processes: the temperature difference method and the pressing
method. The temperature difference method is to heat the inclusion part to expand or to
cool the inclusion part to shrink so that the two are convenient to assemble. When the
assembly body returns to normal temperature, interference will be formed between the two.
 which has difficulty meeting the design requirements of high-performance rotors. In or-
der to make the sleeve produce enough pre-tightening pressure on the magnetic steel,
interference assembly of the sleeve is required on the surface of the magnetic steel [18],
and the two-step method is adopted to prepare the prestressed sleeve. At present, there
are two main interference assembly processes: the temperature difference method and the
Energies 2022, 15, 2467 15 of 22
pressing method. The temperature difference method is to heat the inclusion part to ex-
pand or to cool the inclusion part to shrink so that the two are convenient to assemble.
When the assembly body returns to normal temperature, interference will be formed be-
The
tweenpressing
the two.method refers to
The pressing the interference
method assembly
refers to the method
interference by which
assembly the contained
method by which
part is directly part
the contained pressed into thepressed
is directly containing
into part by a press [61].
the containing A schematic
part by diagram
a press [61]. of the
A schematic
interference assembly of the composite material sleeve by the two-step method
diagram of the interference assembly of the composite material sleeve by the two-step is shown in
Figure 9. Zhou [40] assembled the sleeve interference on the surface of magnetic
method is shown in Figure 9. Zhou [40] assembled the sleeve interference on the surface steel with
an oil press after
of magnetic steeltraditional
with an oiltension winding.
press after traditional tension winding.

Figure 9. Preparation
Figure 9. Preparation of
of prestressed
prestressed sleeve
sleeveby
bythe
thetwo-step
two-stepmethod.
method.

The interference assembly

The interference assemblymethod
methodhas has some
some disadvantages
disadvantages suchsuch as complicated
as complicated pro-
processes and difficult realization of interference. When the interference
cesses and difficult realization of interference. When the interference assembly using assembly using
the
the temperature
temperature difference
difference method
method is is adopted,the
adopted, thethermal
thermalexpansion
expansion coefficient
coefficient ofof carbon
carbon
fiber
fiber is
is low,
low,and
andcold
cold contraction
contractionassembly
assemblyof ofthe
the rotor
rotorcan
can only
only be
be used,
used, resulting
resulting inin small
small
interference of the contraction fit and limited pressure on magnetic steel [24].
interference of the contraction fit and limited pressure on magnetic steel [24]. Interference Interference
assembly
assembly by by the
the pressing
pressingmethod
methodis is prone
proneto to damage
damage[62] [62] and
and is
is not
not suitable
suitable for
for the
the sleeve
sleeve
formed from fiber-reinforced composite material
formed from fiber-reinforced composite material [17]. [17].

4.2. Preparation of Prestressed Sleeve by the One-Step Method

With the emergence of a high-precision tension control system (>200 N/yarn), the
continuous optimization of fiber wear prevention measures in the yarn path, and the devel-
opment of dry winding technology with pre-impregnation, the fiber winding stress level
can reach 7~15% of its strength value without damaging the fiber [63]. By controlling the
fiber tension, high-tension winding technology can exert a higher preload on the structure,
replacing the traditional mechanical interference methods such as hot/cold sleeve, press-
fitting, and bolt preload, realizing the manufacturing of lightweight composite structure
with high prestress, high strength, and small deformation. Preparation of the prestressed
sleeve by the one-step method is shown in Figure 10. It has been well applied in high-
tech electromagnetic equipment of high-speed rotating machinery such as a high-speed
centrifuge rotor and composite flywheel [63]. In recent years, researchers [10,17,28,39–41]
have adopted the high-tension winding method to prepare the carbon fiber sleeve for the
rotor of permanent magnet motor, and the one-step method is used to form the sleeve pre-
tightening, which provides pre-tightening force for the permanent magnet while preparing
the carbon fiber sleeve, and can make the stress distribution of the sleeve uniform by
designing the tension of the winding layer.
 in high-tech electromagnetic equipment of high-speed rotating machinery such as a high-
speed centrifuge rotor and composite flywheel [63]. In recent years, researchers
[10,17,28,39–41] have adopted the high-tension winding method to prepare the carbon
fiber sleeve for the rotor of permanent magnet motor, and the one-step method is used to
form the sleeve pre-tightening, which provides pre-tightening force for the permanent
Energies 2022, 15, 2467 16 of of
magnet while preparing the carbon fiber sleeve, and can make the stress distribution 22

the sleeve uniform by designing the tension of the winding layer.

Figure 10. Preparation

Figure 10. Preparation of
of prestressed
prestressed sleeve
sleeve by
by the
the one-step
one-step method.
method.

Due to the elastic relaxation caused by the shrinkage of the inner composite material
Due to the elastic relaxation caused by the shrinkage of the inner composite material
by the extrusion of the outer layer when the composite material is wound, the thermal
by the extrusion of the outer layer when the composite material is wound, the thermal
relaxation caused by the mismatch between the core mold and the thermal expansion
relaxation caused by the mismatch between the core mold and the thermal expansion co-
coefficient of the composite material during hot curing, and the flow relaxation caused
efficient of the composite material during hot curing, and the flow relaxation caused by
by the pressure driving due to the decrease in the viscosity of the resin during curing,
the pressure driving due to the decrease in the viscosity of the resin during curing, the
the prestress relaxation occurred during the molding process. To solve the problem of
prestress relaxation
prestressing occurred
relaxation, in situduring the molding
consolidation process.
additive To solve the
manufacturing problem of
technology canpre-
be
stressing
used relaxation,
to reduce in situ
the flow consolidation
relaxation during additive
winding manufacturing
and the thermal technology can be
relaxation used
during
to reduce
curing, the flow
to realize therelaxation
efficient andduring winding preparation
high-quality and the thermal relaxation during curing,
of components.
to realize the efficient and high-quality preparation of components.
The thermoplastic composite material can achieve in situ consolidation and winding,
Thematerial
and the thermoplastic
has only composite materialin
physical changes can
theachieve
molding in process,
situ consolidation
high moldingand efficiency,
winding,
and short
and the material
moldinghas only
time, and physical changes
is suitable in the molding process,
for high-performance high sleeves.
motor rotor moldingTher-
effi-
ciency, and short molding time, and is suitable for high-performance
moplastic composites have become a research hotspot, and many achievements have been motor rotor sleeves.
Thermoplastic
made composites
in materials, processhave become aand
equipment, research
processhotspot,
controland many
[64]. achievements
Nanjing University have
of
been made in materials, process equipment, and process control [64].
Aeronautics and Astronautics took the lead in studying the application of thermoplastic Nanjing University
of Aeronautics
composite and
in situ Astronautics
forming took the
in prestress lead in studying
manufacturing [42].the application
Through of thermoplastic
a single-factor experi-
composite
ment in situ forming
and response surfaceinanalysis
prestress manufacturing
experiment, [42]. Through
the optimal formingaprocess
single-factor exper-
considering
iment and
winding response
tension wassurface
obtained. analysis experiment, the optimal
A thermo-mechanical couplingforming
model wasprocess considering
established, and
the reason for prestress relaxation caused by the heat effect was analyzed by laser heating
and winding experiments.
With the increase in the winding tension level, higher requirements of structural stiff-
ness, tension uniformity, and mechanical stability are put forward for winding equipment.
To prevent the influence of rotor magnetic steel on winding equipment, the moving parts of
the forming equipment in the area affected by the magnetic field should be treated without
magnetization. Winding yarn will have a large additional bending moment at the roll
passing point, which can easily cause yarn damage. If the equipment space allows, the
diameter of the roll passing should be properly enlarged to reduce the additional bending
moment of the roll passing on the yarn. In the process of high-tension winding, the wind-
ing equipment carries a large load, so the structural strength and stiffness of the winding
equipment should be strengthened.
In general, the existing composite sleeve is formed by two-step prestressed molding,
but its process is complicated and can easily cause composite damage. One-step prestressed
molding is suitable for the molding of the composite material sleeve and has a certain
research basis, but the existing winding tension is low, which cannot effectively utilize
the high-strength characteristics of composite material, and the subsequent research can
be carried out for the high-tension winding. The prestress relaxation can be reduced by
Energies 2022, 15, 2467 17 of 22

in situ consolidation. According to the special requirements of the magnetic steel rotor
sleeve winding, the equipment is treated without magnetization to reduce the damage to
the winding yarn and strengthen the strength and stiffness of the equipment.

5. Test of Mechanical Properties of the High Prestressed Composite Sleeve

At present, the experimental study is still the most basic and direct method for evalu-
ating the stress design and preparation quality of composite sleeves. In recent years, the
experimental studies carried out by scholars mainly include preload effect tests, strength
tests, and prototype service tests. Researchers [17,40,41] evaluated the pre-tightening effect
of the sleeve on magnetic steel by testing the strain of magnetic steel and verified the
rationality of sleeve stress design. The sample was prepared with the same material and
the same process, and the strength of the sample was tested [17,26,40,41,65] to evaluate the
preparation quality of the sleeve. The rationality of the sleeve stress design and preparation
quality was comprehensively investigated by manufacturing rotor prototypes and service
tests of the prototype [10,16,18,36,45,57–59,65].

5.1. Test of Pre-Tightening Effect

Researchers [17,40–42] tested the strain changes of magnetic steel under tension wind-
ing by strain gauge to evaluate the pre-tightening effect of the sleeve. The strain test
experiment is shown in the figure below. Cheng [42] tested the strain change of the winding
test piece by sticking the strain gauge on the inner wall of the metal core mold to test the
pressure of the composite sleeve on the metal core mold [17,40,41] with strain gauges at-
tached to the sidewall of magnetic steel to test the compressive stress of composite materials
on magnetic steel. It is found that the experimental results are close to the theoretical ones.

5.2. Strength Test

To explore the strength of a fiber-reinforced composite, the samples were prepared and
tested by using the same molding material and the same molding process. Zhang et al. [65]
tested the strength of the NOL ring after winding molding, and the dispersion coefficient
of the sample is small. M46J/L1000 composite material has high tensile strength, modulus,
and low fracture elongation, which is suitable for use as a sleeve material.
Zu et al. [17,40,41] tested the strength of carbon fiber winding products under different
tensions. They found that with the increase in winding tension, the strength of composite
material samples first increased and then decreased, which was thought to be caused by
serious fiber wear when the tension was higher.
Zhou et al. [26] made flat samples to test the material strength and elastic modulus at
20 ◦ C and 150 ◦ C and found that the strength decreased at 150 ◦ C, but the modulus did
not change much. Two sleeve experimental tubes were manufactured: (1) 5 mm thickness
cylinder, laying layer, and sleeve are exactly the same, testing the annular and axial strength
of the sleeve, and (2) a thickness of 1.4 mm, testing the ultimate circumferential strength.
The centrifugal force of magnetic steel was simulated by a water pressure test, and the
strain change during loading was measured by a strain gauge. The results show that (1) the
experimental values of circumferential and axial stress of 5 mm-thick samples are close
to the theoretical values, and the radial displacement meets the design requirements, and
(2) a 1.4 mm-thick sample test shows that the strength of composite material meets the
design requirements.
The existing evaluation of the molding quality of the sleeve is mostly to test the sample
of the sleeve; there was a lack of quality testing of the installed sleeve. Ultrasonic, infrared,
and other non-destructive testing methods can be used to detect and evaluate the molding
quality of the sleeve.

5.3. Prototype Test

No damage was found in rotor structure through rotor prototype manufacturing and
rotating experiments at the rated speed [10,16,65] or overload speed [18,36,45,58,59,66],
 ple of the sleeve; there was a lack of quality testing of the installed sleeve. Ultrasonic,
infrared, and other non-destructive testing methods can be used to detect and evaluate
the molding quality of the sleeve.

Energies 2022, 15, 2467 5.3. Prototype Test 18 of 22

No damage was found in rotor structure through rotor prototype manufacturing and
rotating experiments at the rated speed [10,16,65] or overload speed [18,36,45,58,59,66],
whichproves
which provesthat
thatthe
thedesigned
designedand andmanufactured
manufacturedsleevesleevecancanmeet
meetthe
thedemands
demandsof ofrotor
rotor
strength. Moreover,
strength. Moreover, the
the rotor
rotor has
has been
been tested
tested for
for aa long
long time
time [16,25,58,66],
[16,25,58,66], and
and the
therotor
rotor
runs stably,
runs stably, which proves
provesthat
thatthetherotor design
rotor designandandmanufacture
manufactureare reasonable. The high-
are reasonable. The
speed permanent
high-speed magnet
permanent magnetmotor
motorprototype
prototypewith
with carbon
carbonfiber
fibersleeve
sleeve and platform
and test platform
manufacturedby
manufactured byZhang
Zhangetetal.
al.[59]
[59]isisshown
shownin inFigure
Figure11. 11.

Figure11.
Figure 11.High-speed
High-speedpermanent
permanentmagnet
magnetmotor
motorprototype
prototypetesting
testingplatform
platform[59].
[59].

Wangetetal.al.[57]
Wang [57] conducted
conducted a destructive
a destructive experiment
experiment running
running for afor a long
long time time at ex-
at extreme
treme temperatures, resulting in cracks at the center of the sleeve under the
temperatures, resulting in cracks at the center of the sleeve under the action of thermal action of ther-
mal stress,
stress, andloss
and the theofloss of magnetism
magnetism of permanent
of permanent magnets.
magnets. To avoid
To avoid the above
the above prob-
problems,
lems, high-modulus
high-modulus carboncarbon fiber material
fiber material can becan be selected
selected to improve
to improve the safety
the safety factorfactor
of theof
Energies 2022, 15, x FOR PEER REVIEWsleeve. The anisotropy
the sleeve. The anisotropy of carbon fiber fiber
of carbon material produces
material radialradial
produces upward contraction
upward 19 ofafter
contraction
23
heating, whichwhich
after heating, is conducive to the to
is conducive permanent magnet
the permanent withstanding
magnet the centrifugal
withstanding force,
the centrifugal
but at the
force, but same
at the time,
same axial
time,elongation; the sleeve
axial elongation; assembly
the sleeve should
assembly leaveleave
should a gapa with the
gap with
magnetic
theBinder ring.
magnetic ring.
et al. [10] manufactured an M1 rotor filled with low-density resin material
Binder et al. [10] manufactured an M1 rotor filled with low-density resin material
between poles and performed a rotation experiment in which sleeve failure occurred at
between poles and performed a rotation experiment in which sleeve failure occurred at
35,000 r/min below the rated speed, as shown in Figure 12.
35,000 r/min below the rated speed, as shown in Figure 12.

(a) (b)
Figure 12. M1 rotor schematic diagram: (a) schematic diagram of magnetic steel arrangement; (b)
Figure 12. M1 rotor schematic diagram: (a) schematic diagram of magnetic steel arrangement;
schematic diagram of additional bending force.
(b) schematic diagram of additional bending force.
According
Accordingtotothe thetheoretical
theoreticalcalculation,
calculation,the thesleeve
sleevestress
stressatat35,000
35,000r/min
r/min is is
less
lessthan
than
the
the allowable strength of the material. It was found that the failure position of thesleeve
allowable strength of the material. It was found that the failure position of the sleeve
was
wasclose
closetotothe
thegap
gapbetween
betweenthe themagnetic
magneticpolespolesofofthe
themagnetic
magneticsteel.steel.It Itwas
wasjudged
judgedthat that
the
the failure of the sleeve might be caused by the increased stress of the sleeve caused byby
failure of the sleeve might be caused by the increased stress of the sleeve caused the
the temperature
temperature rise
rise inin the
the rotor
rotor andand
thethe effect
effect of of
thethe axial
axial stress
stress ononthethe sleeve,
sleeve, especially
especially the
the bending
bending stress
stress between
between thethe poles
poles andandthethe stress
stress concentration
concentration at at
thethe
edgeedgeof of
thethe mag-
magnetic
netic steel. It is consistent with finite element calculation that the maximum stress of the
sleeve is between the poles.
Then, an M2 rotor without a pole gap was prepared, as shown in Figure 13, a thin
layer of glass fiber was added to the inner layer of carbon fiber to withstand the bending
effect of block permanent magnet, and the bending effect was expected to be eliminated.
The rotor can run stably at the rated speed of 40,000 r/min.
 sleeve is between the poles.
Then, an M2 rotor without a pole gap was prepared, as shown in Figure 13, a thin
layer of glass fiber was added to the inner layer of carbon fiber to withstand the bending
effect of block permanent magnet, and the bending effect was expected to be eliminated
Energies 2022, 15, 2467 The rotor can run stably at the rated speed of 40,000 r/min. 19 of 22
In summary, the existing test experiments for the performance of composite materia
sleeves are relatively single, and the use of advanced performance characterization meth
ods isItinsufficient.
steel. There
is consistent with is aelement
finite lack of testing of prestressing
calculation distribution
that the maximum stress ofand
the molding
sleeve qual
isity
between the poles.
of the sleeve after preparation. At the same time, the test characterization of the roto
Then, an
in service M2 rotor
is too without
few, and the aexperimental
pole gap was study
prepared, as shownstress,
of real-time in Figure 13, a thin
damage, and evolu
layer of glass fiber was added to the inner layer of carbon fiber to withstand
tion of composite sleeves are not enough. In addition, the performance of the the bending
sleeve unde
effect of block permanent magnet, and the bending effect was expected to be eliminated.
the influence of fatigue, vibration, and other complex loads is still lacking.
The rotor can run stably at the rated speed of 40,000 r/min.

Figure 13.M2
Figure13. M2rotor schematic
rotor diagram.
schematic diagram.

In summary, the existing test experiments for the performance of composite material
6. Conclusions and Further Study
sleeves are relatively single, and the use of advanced performance characterization methods
is insufficient. There is a lack of testing of prestressing distribution and molding quality
of the sleeve after preparation. At the same time, the test characterization of the rotor in
service is too few, and the experimental study of real-time stress, damage, and evolution of
composite sleeves are not enough. In addition, the performance of the sleeve under the
influence of fatigue, vibration, and other complex loads is still lacking.

6. Conclusions and Further Study

In light of the developed analysis, the fiber-reinforced composite material sleeve
has very obvious performance advantages and shows great value in the application of
surface-mounted high-speed permanent magnet motors. However, the stress design and
preparation of the composite material sleeve is a multi-process, multi-level, complex, com-
prehensive problem. In order to better apply high-performance fiber-reinforced composite
materials to motor sleeves, this paper summarizes the design and manufacture of sleeve
stress from the aspects of sleeve material, stress design, prestress preparation, and testing.
With the development of high-performance motors, composite sleeves must continue
to improve. Based on the existing research and development status, the prospect of the
development of a fiber composite sleeve is put forward:
1. The application of quick-curing thermosetting composite or in situ forming thermo-
plastic composite is the basis to improve the effect of sleeve pre-pressing.
2. Optimizing the design and manufacturing mode of the sleeve is the key to improving
the forming efficiency of the sleeve. In order to improve the efficiency of the sleeve
design and manufacture, research on intelligent design and high-tension winding
should be carried out.
3. The follow-up could carry out the quality testing of the forming sleeve, and the
detection and research of the whole life cycle of the sleeve, to ensure the safe and
stable operation of the rotor.
Energies 2022, 15, 2467 20 of 22

Author Contributions: Conceptualization, W.W. and Y.L. (Yong Li); methodology, D.H. and X.C.;
investigation, Y.L. (Yong Li) and W.W.; data curation, W.W. and L.L.; writing—original draft prepa-
ration, W.W. and Y.L. (Yanrui Li); writing—review and editing, W.W., H.L. and Y.L. (Yong Li). All
authors have read and agreed to the published version of the manuscript.
Funding: This research received no external funding.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Data analyzed in this study were a re-analysis of existing data, which
are openly available at locations cited in the reference section.
Conflicts of Interest: The authors declare no conflict of interest.

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