Robust Multidisciplinary Design Optimization of PM Machines With Soft Magnetic Composite Cores for Batch Production

Abstract

This paper presents a robust approach for multidisciplinary design optimization of permanent magnet (PM) motors with soft magnetic composite (SMC) cores to improve their manufacturing quality in batch production. First, a general multidisciplinary design analysis framework is developed for PM-SMC motors, which includes electromagnetic, thermal, modal, and manufacturing analyses. Second, an improved multilevel optimization method is presented to improve the efficiency of the robust optimization. Finally, to demonstrate the effectiveness, a PM-SMC transverse flux machine is investigated. The numerical solutions, including electromagnetic and thermal analyses, are validated by the experimental results. As shown, the proposed method can significantly increase motor’s reliability and greatly reduce the computation cost, which benefits the mass production in industrial applications.