Abstract
Bearingless motors combine torque generation and suspension force capabilities into one electromagnetic actuator. However, design optimization of bearingless motors is more complex than with traditional motor structures. The combined levitation and motoring performance cannot be quickly evaluated by using Computer Aided Design (CAD) tools applied in traditional motor designs. This work proposes a bearingless motor design chain. The initial dimensions of the test case motor are iteratively derived. The levitation performance is verified by using a lumped parameter model. The fine tuning of the rotor geometry is carried out by using the Finite Element Method (FEM). The objectives for the FEM optimization are a minimum torque ripple, minimum levitation force variations, and maximum torque and force capacities. Finally, experimental force angle measurements of a manufactured test case machine with a unique method are provided. Application of differential evolution is presented and discussed in both analytical and in FEM design steps.
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