Rapid Calculation and Optimization of Vibration and Noise of Permanent-Magnet Synchronous Motors for EVs Based on Equivalent Structural Network

Abstract

Optimizing electromagnetic performance and vibration noise performance simultaneously is important when designing the drive motor for electric vehicles (EVs). This has not been fully explored, and there are only a few relevant studies. To achieve simultaneous optimization, this paper proposes an equivalent structural network (ESN) of stator assembly to calculate the modal distribution and harmonic response transfer functions. Based on the ESN model, the motor’s electromagnetic vibration noise harmonic response, such as acceleration and equivalent radiated power level (ERPL), can be quickly calculated. The feasibility of the established ESN model is verified by structural-field finite-element method (FEM) and modal hammer tests. Based on the modern optimization algorithm and the ESN model, an improved multi-physics and multi-objective optimization design approach is proposed for an optimized design of a 30 kW interior permanent-magnet synchronous machine (IPMSM). The motor’s maximum output torque and ERPL were selected as optimization objectives, and then the ERPL and acceleration were recalculated using structural-field FEM to validate the accuracy of the optimal design. Finally, vibration acceleration tests were carried out on a manufactured prototype motor to verify the feasibility and validity of the proposed optimization design method.