Abstract
This paper uses the Taguchi method to optimize the manufacturing process and robust design of a low-cost permanent magnet motor with soft magnetic composite (SMC) cores. For the manufacturing process, SMC cores are produced by using the molding technology without any wire cutting costs. To maximize the relative permeability and minimize the core loss, the Taguchi method is employed to identify the best control factor values for the heat treatment of SMC cores based on a series of experimental results. Due to the manufacturing tolerances, there are significant uncertainties in the core densities and motor dimensions, which will result in big performance variations for the SMC motors in the batch production. To obtain a robust design less sensitive to these tolerances, the conventional Taguchi parameter design method and a sequential Taguchi optimization method are presented to maximize the average torque and minimize the core loss of a low-cost PM motor. Through comparison, it is found that the proposed optimization method is efficient. It can provide an optimal design with better motor performance and manufacturing quality. The proposed method will benefit the industrial production of cost-effective PM-SMC motors with robust and compact designs.
Highlights
Soft magnetic composite (SMC), as a relatively new magnetic material, is a kind of iron powder made of fine particles with thin electrical insulation
The manufacturing process of SMC cores can be totally different from those cores made of steel sheets
Five parameters (θ st, Lgap, Lrt, Wpm, and θ rp ) as shown in Figure 8 are crucial to its performance, where Wpm is the width of the ferrite magnet in the direction of magnetization, Lgap is the length of the air gap, and the others are three parameters for SMC cores
Summary
Soft magnetic composite (SMC), as a relatively new magnetic material, is a kind of iron powder made of fine particles (around 0.1 mm in diameter) with thin electrical insulation. Due to the powder nature, motor cores made of SMC have some advantages compared with cores made of silicon steel sheets, such as lower eddy current loss and isotropic electromagnetic and thermal properties These advantages benefit the design of high-performance permanent magnet (PM) motors with 3D flux path, such as transverse flux machine, axial flux motor, linear brushless motor and claw pole motor [1,2,3,4,5,6]. Regarding the molding technology for SMC cores, an important step is the heat treatment This step cooks the raw core samples in a high-temperature furnace with several temperature control factors, such as the curing temperature and time.
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