Topological optimization of the design of a permanent magnet synchronous motor using a genetic algorithm

Abstract

The operating efficiency of a synchronous motor strongly depends on the design of its component parts, including the arrangement of materials (topology) of the rotor. An important element of the rotor, and at the same time the most expensive, are permanent magnets made of NdFeB material. Topological optimization allows you to reduce the volume of permanent magnets, which will reduce the price of the motor, or switch to cheaper materials, for example, ferrite, while maintaining performance characteristics. A genetic algorithm is used as a search method. And an important feature is that topological optimization is complex; not only electromagnetic parameters are checked, but also the thermal and strength characteristics of a synchronous motor. This test allows us to obtain designs that can be manufactured in practice. The article discusses the developed method of complex topological optimization using a genetic algorithm, optimization results and methods for testing the resulting structures. Optimization allows you to reduce the volume of NdFeB magnets by 2232%, which reduces the cost of the motor by 14–21%, or switch to ferrite magnets, which reduces the cost by 24–33%, while the torque value changes within 2%, which indicates about conservation of torque.