Simulation, Verification and Optimization Design of Electromagnetic Vibration and Noise of Permanent Magnet Synchronous Motor for Vehicle

Abstract

Aiming at the electromagnetic vibration and noise problem of an 8-pole 48-slot permanent magnet synchronous motor for a vehicle, the multi-physics coupling simulation model of the motor is introduced to optimize the rotor structure of the motor to reduce the vibration and noise of the permanent magnet synchronous motor. The effectiveness of the research method is verified by the bench test in the anechoic chamber. Finite element software was used to establish the stator core and system model considering the anisotropy of materials, and the simulation model was verified by modal experiment. For the 2in1 electric drive system, the electromagnetic-structure-acoustic multi-physics coupling noise prediction model is established. Based on the three-dimensional distributed electromagnetic force excitation, the electromagnetic radiation noise of the motor under full load acceleration is calculated, and the characteristics of electromagnetic noise are analyzed. The accuracy of the electromagnetic-structure-acoustic multi-physics coupling model of permanent magnet synchronous motor is verified by the bench test results of the anechoic chamber. By changing the angle and shape of the motor rotor, the cogging torque ripple between the stator and the rotor is reduced, and the 48th order harmonic amplitude is reduced. Finally, the optimized sample is tested on the vehicle, and the 48th order electromagnetic noise can be reduced by 5–15 dB(A). The accuracy of the electromagnetic-structure-acoustic multi-physics coupling model of permanent magnet synchronous motor is verified by the bench test results of the anechoic chamber. Therefore, the research results can be further used for the design and development of a vehicle permanent magnet synchronous motor and the research on the mechanism of electromagnetic vibration and noise.

High-Speed Design with Separated Tapering for Reducing Cogging Torque and Torque Ripple of a 3 kW Dry Vacuum Pump Motor for the ETCH Process

“…The equation for torque is shown in Equation (1). Intuitively, torque can be generated in two ways: the first is the force between the magnet and the magnet, called magnetic torque.…”

“…Equation ( 4) is the expression for calculating the torque ripple. As expressed in Equation ( 4), the torque ripple increases as the range of torque fluctuation increases [1]. There are two causes of such large torque amplitudes: the input current and the mechanical structure of the motor [4,5].…”

“…Recent research efforts to reduce the vibration and noise of motors are actively underway [1]. It is important to reduce torque ripple, a major cause of vibration and noise in motor design [1].…”

“…Recent research efforts to reduce the vibration and noise of motors are actively underway [1]. It is important to reduce torque ripple, a major cause of vibration and noise in motor design [1]. Among the causes of torque ripple, there are reasons related to the mechanical structure [2,3].…”

Analysis and Design Methodology of Radial Flux Surface-Mounted Permanent Magnet Synchronous Motors

“…In most cases, the brief explanation given and the experimental or simulated results are not enough for readers to understand the process in between and to learn how to replicate those results or make their own designs and experiments. Examples of this include [3][4][5][6][7][8][9][10][11][12][13][14][15][16][17][18][19] where motors are designed but the detailed process is not shown.…”