Application-Oriented Robust Design Optimization Method for Batch Production of Permanent-Magnet Motors

Abstract

Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works. 1 Abstract-From the perspective of industrial production, the design and optimization of electrical machines are application oriented, including maximizing production quality and minimizing production cost in terms of different manufacturing conditions. To achieve these goals, this work presents an efficient application-oriented robust design optimization method for permanent magnet (PM) motors. The method consists of two main contributions. The first one is the development of an overall optimization strategy including qualitative and quantitative analyses to provide possible options for an application. Multi-physics analysis, uncertainty analysis, production cost and optimization models need to be investigated. The second one proposes a multilevel optimization method for the high-dimensional robust design problem of each option. To illustrate the advantages of the proposed method, PM motors with soft magnetic composite cores are investigated for domestic applications. The design optimization is conducted in terms of three motor options and three batch production volumes for both conventional deterministic and robust approaches, and it consists of eighteen high-dimensional multi-physics optimization problems in total. Main optimization results are presented and discussed. Experimental and simulation results are presented to validate the effectiveness of the proposed models and methods.

A Review of Design Optimization Methods for Electrical Machines

“…It will also enable the designers to develop production cost models of electrical machines. Currently, estimation of production cost is a big challenge for electrical machines [116][117][118]. Integrated product and process development method can be employed to address this challenge [118,119].…”

Robust Design of a Low-Cost Permanent Magnet Motor with Soft Magnetic Composite Cores Considering the Manufacturing Process and Tolerances

“…The manufacturing process of SMC cores can be totally different from those cores made of steel sheets. Taking advantage of the powder metallurgy technology, the SMC cores can be produced by molding technology [1,[7][8][9]. This kind of technology can be used to produce SMC cores with complex structures that may be hard or even impossible to manufacture by the traditional lamination method [10].…”

“…High-performance NdFeB magnets have been used in many PM-SMC motors, such as transverse flux machine and axial flux motor to achieve good performance [1][2][3][4][5][6][7][8][9]11]. However, they are very expensive.…”

“…Due to the uncertain pressure employed in the powder compaction process, the densities of the SMC cores vary significantly, which will affect the magnetization curves of these cores and result in big variations to the motor performances [7][8][9]. There are some manufacturing tolerances for other parts of the PM-SMC motors as well, such as the dimension of the ferrite magnet and the length of the air gap.…”

Design, Analysis and Model Predictive Control of an Axial Field Switched-Flux Permanent Magnet Machine for Electric Vehicle/Hybrid Electric Vehicle Applications

“…To reduce the computational time and the cost as well, the optimization algorithms, such as genetic algorithm [24], particle swarm optimization algorithm [25] and difference evolution algorithm [26], have been presented. Recently, many alternatives such as surrogate-assisted model [27] which emulates the behavior of the real machine performance, is less accurate but much faster, have also been emerged to improve the optimization efficiency of electrical machines, especially for those machines with 3-D flux topologies which requires 3-D FEM, such as the transverse and axial flux as well as claw pole machine. The characteristics of several optimization design models, methods and strategies for electrical machine are summarized and analyzed in [28].…”