Rotor Shape Multi-Level Design Optimization for Double-Stator Permanent Magnet Synchronous Motors

Abstract

This research presents a rotor shape multi-levelobjective optimization designed to reduce the mechanical stress distribution in the rotor core of a double-stator permanent magnet synchronous motor. The second objective is weight minimization performed via a response surface methodology (RSM) with a uniform precision central composite design (UP-CCD) function. The optimal operation point, with a substantial population size, is reached using a Monte Carlo algorithm on the fitted model. The goodness-of-fit for the model is evaluated based on the modified Akaike information criterion (AICc) and the Bayesian information criterion (BIC) with a linear regression approach. To achieve these goals, a multi-level design procedure is proposed for the first time in machine design engineering. All the electromagnetic forces of the machine such as normal, tangential, and centrifugal forces are calculated using 3-D transient finite element analysis (FEA). The outcome of the proposed rotor core optimization shows that the finalized shape of the studied core has significantly smaller weight and mechanical stress, while the electromagnetic performance of the machine has remained consistent with a pre-optimized machine.

A physics-informed Bayesian optimization method for rapid development of electrical machines

“…Among all types of synchronous motors without electric current in their rotor, permanent magnet synchronous machines (PMSM)s gained significant consideration in the electric vehicle (EV) market recently 1 , 2 . This is due to their high performance, such as high torque at low operational speeds and efficient and reliable inverters.…”

“…The use of design optimization in electrical machines accomplished significant performance improvements and developments. Many researchers used deterministic methods 2 , 5 , 15 – 18 , stochastic 19 (e.g. genetic 20 – 22 and particle swarm 23 – 25 algorithms) methods, and machine learning (ML) methods 1 , 26 – 33 , such as Bayesian optimization (BO) algorithms 31 , 34 , to improve different aspects of motor performance.…”

Analytical modelling for magnetic field of interior permanent magnet synchronous motors accounting for bridge saturation

“…In recent years, interior permanent magnet synchronous motor (IPMSM) is widely used in many industrial fields, such as electric vehicles and aerospace, due to its high-power density and wide speed range [1][2][3]. The analytical method is important for the initial design stage of motors [4][5][6]. However, the rotor structure of the IPMSM is complex, and the non-linear saturation exists in the rotor bridge region.…”

Performance Improvement for double-stator permanent magnet synchronous machine using analytical subdomain model

“…Wang et al 2019) for usage with electric vehicles (EVs) and dual-channel magnetically integrated charger operations. While additional DS-PMSM types have been researched for their potential to minimize mechanical stress and weight while keeping the same power density (Asef et al 2018).…”