Abstract
This paper presents the design and fabrication schemes of a magnetic system consisting of segmented permanent magnet (PM) blocks, back-iron and frame structures. Here, a frame structure aims to bind PM blocks and iron structure. Non-intuitive design of segmented PMs and back-iron are obtained using multi-material topology optimization formulation. Subsequently, a non-magnetic frame structure is designed through a post-processing procedure, which is proposed using the smoothed fields of optimized PM and back-iron densities. Final design results are converted into computer-aided design (CAD) models and fabricated using conventional or additive manufacturing techniques. Segmented PM blocks, and back-iron structures are processed using water-jet cutting and wire electrical discharge machining, respectively. A frame structure is fabricated by additive manufacturing using a multi-jet printing machine. Using the proposed schemes, two magnetic systems are successfully designed and fabricated, respectively, for maximizing the magnetic field inside a rectangular cavity, and maximizing the magnetic force generated with a C-core electromagnet.
Highlights
A magnetic system combining permanent magnets (PMs) and back-iron structure is a key component used in a wide range of applications
This paper aims to present the design and fabrication of a magnetic system consisting of segmented PM blocks, backiron and frame structures
A design approach based on multi-material topology optimization is proposed, and design results are fabricated using conventional and additive manufacturing techniques
Summary
A magnetic system combining permanent magnets (PMs) and back-iron structure is a key component used in a wide range of applications. Structural topology optimization is an effective design tool that can produce non-intuitive design (i.e. structural shape and configuration) for a given design goal. Since it was first proposed in structural stiffness problems [1], topology optimization has been successfully extended to various physical disciplines [2] such as thermal fluid [3], and electromagnetic problems [4], [5]. In [6], a PM with continuously varying magnetization direction is designed by setting a magnetization direction as a design variable of topology optimization. Such a PM is not preferred due to difficulties
Sign-in/Register to view highlights & summary 
Published Version (
Free)
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call