This study analyzed design factors to maximize energy efficiency, via numerical analysis, through an examination of the characteristics of a heating system that uses permanent magnets and is employed for preheating in the aluminum cladding extrusion process. The design parameters of the billet heater using permanent magnets are the magnetic flux direction, the number of magnets, clearance, and eccentricity. The magnetic flux density, current density, power loss, temperature, and energy consumption characteristics were examined using the results of the parameter variations. Numerical analysis for the base model was conducted, and it was experimentally verified that the aluminum billet reached 450 °C in about 260 s, and the temperature error at that time was about 2%. The analysis results show that the optimal factor conditions vary significantly depending on the magnetic force direction of the permanent magnet, that is, the circumferential (tangential) and centrifugal (normal) directions. Furthermore, eccentricity has an effect on efficiency in general, and the narrower the clearance was between the magnet and billet, the higher the efficiency achieved. That is, it was confirmed that the power loss increased by about 1.79% in the four permanent magnets to the tangential model, and increased by about 10.51% in the 12 permanent magnets to the tangential model when an eccentricity of 2 mm was applied at a clearance of 2.5 mm. In addition, the optimal design parameters of a system that heats aluminum billets with a diameter of 60 mm and a length of 70 mm were proposed, and the importance of the design parameters was revealed. In this study, it was found that 12 magnets were the most effective when the magnetic flux pole direction was tangential.
With the increasing proliferation of electric and hydrogen vehicles, noises to recognize the driving status at low speeds are legalized, so a virtual engine sound generator is required, and slimming is required for packaging it in vehicles. This study investigates an optimization method for improving the electromagnetic force performance and slimming of the magnetic circuit for the permanent magnet structure for the vertical magnetization of the actuator for the acoustic vehicle alerting system (AVAS) of a vehicle and the probabilistic optimization of manufacturing tolerance management. To investigate the impact of the design parameters of the magnetic circuit structure on the electromagnetic force performance and slimming, we performed an independent analysis based on a single variable and investigated the characteristic variations based on multiple variables using a full factorial design and derived a performance prediction regression model using the central composite design of response surface methodology, including the curvature effect, by adding a center point to verify and consider the nonlinear characteristics. Consequently, four effective design parameters were determined to analyze the electromagnetic force performance and slimming of the vertical magnetization structure of the AVAS actuator—permanent magnet thickness, magnetic force collecting plate thickness, yoke position, and yoke thickness. We then performed statistical analysis using Monte Carlo simulation and proposed an optimization management level of 3σ with excellent process capability as the design application tolerance that can occur in the manufacturing process of each design parameter, whereby the confidence level of electromagnetic force performance and slimming improved from 99.46% to 99.73% and 97.62% to 99.73%, respectively.
In this paper, an optimal design model was developed to reduce noise and secure the torque performance of a brushless direct-current motor used in the seat of an autonomous vehicle. An acoustic model using finite elements was developed and verified through the noise test of the brushless direct-current motor. In order to reduce noise in the brushless direct-current motor and obtain a reliable optimization geometry of noiseless seat motion, parametric analysis was performed through the design of experiments and Monte Carlo statistical analysis. The slot depth, stator tooth width, slot opening, radial depth, and undercut angle of the brushless direct-current motor were selected as design parameters for design parameter analysis. Then, a non-linear prediction model was used to determine the optimal slot depth and stator tooth width to maintain the drive torque and minimize the sound pressure level at 23.26 dB or lower. The Monte Carlo statistical method was used to minimize the deviation of the sound pressure level caused by the production deviation of the design parameters. The result is that the SPL was 23.00–23.50 dB with a confidence level of approximately 99.76% when the level of production quality control was set at 3σ.
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