Abstract
With the increasing proliferation of electric and hydrogen vehicles, noises to recognize the driving status at low speeds are legalized, so a virtual engine sound generator is required, and slimming is required for packaging it in vehicles. This study investigates an optimization method for improving the electromagnetic force performance and slimming of the magnetic circuit for the permanent magnet structure for the vertical magnetization of the actuator for the acoustic vehicle alerting system (AVAS) of a vehicle and the probabilistic optimization of manufacturing tolerance management. To investigate the impact of the design parameters of the magnetic circuit structure on the electromagnetic force performance and slimming, we performed an independent analysis based on a single variable and investigated the characteristic variations based on multiple variables using a full factorial design and derived a performance prediction regression model using the central composite design of response surface methodology, including the curvature effect, by adding a center point to verify and consider the nonlinear characteristics. Consequently, four effective design parameters were determined to analyze the electromagnetic force performance and slimming of the vertical magnetization structure of the AVAS actuator—permanent magnet thickness, magnetic force collecting plate thickness, yoke position, and yoke thickness. We then performed statistical analysis using Monte Carlo simulation and proposed an optimization management level of 3σ with excellent process capability as the design application tolerance that can occur in the manufacturing process of each design parameter, whereby the confidence level of electromagnetic force performance and slimming improved from 99.46% to 99.73% and 97.62% to 99.73%, respectively.
Highlights
The automotive industry is shifting its focus from vehicles with internal combustion engines to electric vehicles, powered by advancements in technology and increased environmental awareness of global warming
The tolerance of design parameters for the magnetic circuit was optimized by calculating the standard deviation at the 3σ level of design tolerance for each parameter, and stochastic analyses were performed based on the sensitivity of the design parameters, electromagnetic force performance distribution, and thickness variation by the probabilistic analysis method after generating1.00%
As a result of optimizing the multi-objective function to minimize the boundary conditions of the design parameters and the magnetic circuit thickness and maximize the electromagnetic force, the magnetic circuit thickness was estimated at 19.40 mm, and the electromagnetic force was estimated at 20.02 N
Summary
The automotive industry is shifting its focus from vehicles with internal combustion engines to electric vehicles, powered by advancements in technology and increased environmental awareness of global warming. Wagner and Gajda assumed that the manufacturer should comply with the AVAS minimum sound pressure level on all sides of the vehicle, making the warning sound excessive in a specific direction depending on the AVAS speaker installation method [15] To address this problem, studies are underway, and it has been verified that high-quality warning sounds can be generated by creating a sound field controllable with a loudspeaker-based system [16,17]. The size and shape of the actuator are factors that affect panel excitation and vibration, and their performance can be improved by optimizing the magnetic circuit considering the design boundaries. AVAS actuator mounted on structure, a vehicle hood dependingthe ondesign the magnetic circuit strucand design the electromagnetic force performance and slimming of theparameters se‐.
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