A high-speed squirrel-cage induction machine requires a totally different design compared to the traditional squirrel cage industrial motor because of the mechanical limitations caused by the high speed. This results in a more complicated rotor construction and expensive material selection, and sets higher standards for the manufacturing precision. The objective of this paper is to demonstrate the design aspects, material selection, and manufacturing of a squirrel cage rotor for high-speed applications. In this paper, the rotor dimensioning approach based on equations and data analysis is presented. Rotor material selection and construction topology influence on the electrical machine design are discussed. The results are illustrated with the design of a 6 kW, 120 000 rpm induction machine for a turbo-circulator. The rotor parameters' influence on the electromagnetic performance of the designed machine is demonstrated. Mechanical stresses for different topologies are studied with Finite Element Method (FEM) analysis. Several manufacturing methods for producing a high precision rotor are described and compared. The presented rotor design approach, which enables high electromagnetic performance and robust construction, is verified by the testing of a prototype.

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