Abstract
For the optimization of three-phase hybrid stepper motors with complex electromagnetic structures, an optimization method is presented in this paper. The method is a combination of 3D-FEM and the Taguchi optimization method intended to reduce the dependence on FEM results during the optimization calculation. In this paper, the optimization method is used in the optimization of the tooth shape of the three-phase hybrid stepper motor, and the objective is to reduce the noise caused by harmonics in the “torque-angle characteristic” of the motor. It is clear that traditional optimization methods make it very difficult to carry out such an optimization calculation as a large number of finite element calculations have to be used in the optimization process, and the required computation time is extremely long. Using the optimization method presented in the paper, the optimization becomes feasible because the number of finite element calculations is greatly reduced and the computation time is thus greatly reduced. In order to check the effectiveness of the optimization, the waterfall diagram for noise analysis and its application to check torque ripple are also presented in the paper. Both simulation and test results show that the optimized structure can significantly reduce the motor noise caused by torque ripple. Therefore, the optimization method proposed in this paper can be an effective tool for the optimal design of high-performance motors, including stepper motors.
Highlights
Hybrid stepper motors (HSMs) are widely used in control systems because of their high positioning accuracy, compact size, and lower operation noise [1]
It is clear that traditional optimization methods make it very difficult to carry out such an optimization calculation as a large number of FE calculations have to be used in the optimization process, and the required computation time is so long that optimization using
Compared with the initial prototype, the noise amplitude of THD-min 3P-HSM was significantly reduced, especially the reduction in the harmonic noise by 6 times, as well as the reduction in the higher harmonics, indicating that the torque ripple was improved in the optimized motor; this means that the optimization of the tooth shape was effective
Summary
Hybrid stepper motors (HSMs) are widely used in control systems because of their high positioning accuracy, compact size, and lower operation noise [1]. This paper presents the Taguchi method for the optimization of the EM structure of HSMs. The aim of the optimization is to reduce the torque ripple and operation noise of the motor [8]. The drive current generates EM torque ripples, and induces the vibration and acoustic noise in the motor’s operation [7]. This noise type is not discussed here. Optimizing the motor tooth shape to reduce the THD is an effective method in terms of reducing motor cogging torque and improving motor noise. A method that combines the Taguchi method with FEM is introduced to optimize the tooth structure This method can significantly reduce the results obtained via the FEM. The testing results of the optimal THD-min 3P-HSM confirm the effectiveness of the optimization method
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