We carried out FEM simulations for modeling ultra-high-speed universal motors by using the state function method and analyzed the phenomenon of commutator sparking, the characteristics of the air gap surface, and the contact condition or contact resistance of the brushes and commutator bars. Thus, we could quantitatively analyze commutator sparking and investigate the configuration of the iron core. The results of FEM analysis were used to develop a model for predicting the configuration of the iron core and for estimating the electromotive force generated by the transformer, armature reaction field, spark voltage, contact resistance between the rotating brushes, and changes in the gap permeance. The results of our simulation were experimental results. This confirmed the validity of our analysis method. Thus, an ultra-high-speed, high-capacity of 1.5kw motor rotating at 30,000rpm can be designed for use in vacuum cleaners.
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