Abstract
This paper proposes an optimal design for a surface mounted permanent magnet synchronous machine (SM-PMSM) based on parametric optimization process to reduce the on-load Back-EMF distortions caused by an increase in the electromagnetic load and in the saturation. Unlike conventional methods described in the literature, the optimization approach proposed here accounts for the saturation effects, air gap flux density distribution and the evaluation of the on-load Back-EMF by means of finite element analysis, allied to the most recent on-load Back-EMF evaluation method, known as the Back-EMF MST (Maxwell stress tensor) method. Furthermore, the optimization process is performed considering either the machine's physical symmetry (based on pole numbers) and its nonevident symmetry (based on saturation effects and on the relevance of each tooth in the Back-EMF waveform), which is identified using the Back-EMF MST method. The proposed optimization process also analyzes different sets of variables based on symmetric and asymmetric tooth dimensions. The result is a machine with a reasonably improved design, higher average torque, lower torque ripple and smaller volume. In addition, the on-load Back-EMF is almost identical to the no-load one. Hence, the on-load cogging torque is almost identical to the no-load cogging torque.
Highlights
The search for optimal design parameters during the design and manufacturing of electrical machines has been the focus of attention of numerous researchers, engineers and companies around the world
In recent decades, optimization processes have been challenged and driven [1]-[5], on the one hand, by new requirements established by different standards around the world (NEMA, IEC 60034-30, IE1, IE2, IE3, IE4, IE5, NBR 17094-1, AS/NZS 1359.5-2004, etc.) for more efficient machines. These processes have been supported by the evolution of even faster computers, cloud computing, parallel processing and new analytical and numerical methods [6]-[11]. When it comes to the design optimization of permanent magnet synchronous machines (PMSM), the majority of published articles and procedures focus on reducing the electromagnetic torque ripple, a Brazilian Microwave and Optoelectronics Society-SBMO
The investigation was divided into three case studies: 1 – Optimization of 6 stator teeth (1⁄4 of the machine) with a symmetric set of variables, whose shape and dimensions are replicated in the remaining 3⁄4 of the machine. 2 – Optimization of 2 stator teeth with a symmetric set of variables. 3 – Optimization of 2 stator teeth with an asymmetric set of variables
Summary
The search for optimal design parameters during the design and manufacturing of electrical machines has been the focus of attention of numerous researchers, engineers and companies around the world. These processes have been supported by the evolution of even faster computers, cloud computing, parallel processing and new analytical and numerical methods [6]-[11]. When it comes to the design optimization of permanent magnet synchronous machines (PMSM), the majority of published articles and procedures focus on reducing the electromagnetic torque ripple, a Brazilian Microwave and Optoelectronics Society-SBMO received 29 Oct 2018; for review 1 Nov 2018; accepted 25 July 2019. This approach is focused on stator teeth dimensions (width, height, tooth-tip, tooth-shoes, slot-opening width, etc.) and stator yoke thickness, using Differential Evolution (DE) [7]; or on the shape and size of permanent magnets (PMs), using Topology Optimization (TO) [8]; or on rotor parameters and dimensions (including flux barriers – shape, position and dimensions) using Genetic Algorithms (GAs) and the Kriging Method (KM) [9]-[10]
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