Abstract
The improvement of the robustness of the performance of electrical machines in presence of neglected features, such as manufacturing tolerances and deviations in material properties and parameters, is increasingly demanded. The available optimization procedures do not account for manufacturing tolerances, leaving the decision process incomplete. The article proposes a methodology for the selection of the more robust design towards manufacturing tolerances among the best candidates, detected by an optimization procedure. Statistical tools for tolerance analysis and worst-case analysis are discussed and adopted for the scope. The proposed methodology is used to select a robust design with respect to torque ripple deviations due to geometric tolerances in the laminations of a Synchronous Reluctance Motor with fluid shaped barriers. The statistical performance analysis and the worst-case analysis provide an estimation of the performance deterioration in the presence of the tolerances in the manufacturing process.
Highlights
T HE optimization of an electric machine design is based on appropriate models, adopting different parameters, geometric details, and material characteristics [1], [2].The complexity and the accuracy of the models depend on the design steps
The sensitivity analysis is typically adopted in tolerance analysis to identify the design variables where Manufacturing Tolerances (MTs) are more impacting
The sensitivity analysis evaluates the impact on the specific performance of a slight deviation of each specific design variable in the machine model
Summary
Andrea Credo , Student Member, IEEE, Giuseppe Fabri , Member, IEEE, Marco Villani , and Mircea Popescu , Fellow, IEEE. The available optimization procedures do not account for manufacturing tolerances, leaving the decision process incomplete. The article proposes a methodology for the selection of the more robust design towards manufacturing tolerances among the best candidates, detected by an optimization procedure. The proposed methodology is used to select a robust design with respect to torque ripple deviations due to geometric tolerances in the laminations of a Synchronous Reluctance Motor with fluid shaped barriers. The statistical performance analysis and the worst-case analysis provide an estimation of the performance deterioration in the presence of the tolerances in the manufacturing process. Density distribution Lower and upper fillet of the slot Fillet Finite Element Phase current Current density Local Minimums Manufacturing Tolerances Number of laminations Number of rotor barriers Outer rotor diameter Outer stator diameter Generic performance. Color versions of one or more of the figures in this article are available online at https://ieeexplore.ieee.org
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