In this study, we introduce an optimal design for a spoke-type interior permanent magnet (IPM) motor that can minimize PM weight by allowing irreversible demagnetization, unlike the conventional motor design method that does not allow irreversible demagnetization. The spoke-type rotor structure has the advantage of concentrating the magnetic flux around the rotor core. However, part of the PM near the surface of the stator tooth becomes sensitive to the armature reaction and external magnetic factors. Therefore, typical spoke-type rotor construction follows a limited design process that does not allow irreversible demagnetization. Although the manufacturing process allows tolerance for the demagnetization rate, motor design without considering the demagnetization rate in all the design stages becomes a design constraint and limits the performance area. In this study, the performance improvement is examined, when irreversible PM demagnetization is allowed up to −3%, and is not zero. For optimal design, Latin hypercube sampling (LHS), the kriging model, and genetic algorithm (GA) are utilized. With the proposed design process, motors are effectively designed to reduce the PM weight by 23.7%, compared to the initial design model while maintaining an efficiency almost similar to that of the initial design model. INDEX TERMS Brushless AC motor, spoke-type interior permanent magnet motor, NdFeB magnet, irreversible demagnetization, demagnetization rate, armature reaction. KEUN-YOUNG YOON (Member, IEEE) received the B.S. degree in electronic and computer engineering, the M.S. degree in electronic, electrical, control, and instrumentation engineering, and the Ph.D. degree in mechatronics engineering from
In this paper, we propose and evaluate a robust design optimization (RDO) algorithm for the shape of a brushless DC (BLDC) motor used in an electric oil pump (EOP). The components of the EOP system and the control block diagram for driving the BLDC motor are described. Although the conventional deterministic design optimization (DDO) method derives an appropriate combination of design goals and target performance, DDO does not allow free searching of the entire design space because it is confined to preset experimental combinations of parameter levels. To solve this problem, we propose an efficient RDO method that improves the torque characteristics of BLDC motors by considering design variable uncertainties. The dimensions of the stator and the rotor were selected as the design variables for the optimal design and a penalty function was applied to address the disadvantages of the conventional Taguchi method. The optimal design results obtained through the proposed RDO algorithm were confirmed by finite element analysis, and the improvement in torque and output performance was confirmed through experimental dynamometer tests of a BLDC motor fabricated according to the optimization results.
This study demonstrates that the use of a flared-shape rotor structure in interior permanent magnet (IPM) permanent magnet synchronous motor (PMSM) yields better performance than the basic IPM PMSM motor, using a spoke structure with ferrite magnets. To concentrate the effective magnetic flux, the proposed rotor structure is composed of a number of ferrite magnets, which are inserted in a flared shape in the rotor core. This paper shows the comparison with the analysis results of 2D finite element method (FEM), and it is shown that the proposed IPM PMSM motor can be an effective substitute for the basic IPM PMSM motor, which requires low torque ripple and high efficiency. In particular, the proposed flared IPM PMSM motor has lower pulsation of torque and superior efficiency, as well as lower acoustic noise and vibration, compared to the basic IPM PMSM motor. To verify the performance improvement of the proposed model, a prototype of the proposed model was manufactured. It was experimentally confirmed that the proposed model has lower torque ripple and higher efficiency than the basic model. Based on this performance improvement, the proposed flared IPM PMSM motor is suitable for electric vehicles and home appliances.
The irreversible demagnetization of permanent magnets causes the deterioration of the performance in permanent magnet synchronous motors (PMSMs), which are used for electric vehicles. NdFeB, which is the permanent magnet most commonly used in PMSMs for electric vehicles, is easily demagnetized at high temperatures. Because traction motors for electric vehicles reach high temperatures, and a high current can be instantaneously applied, permanent magnets of PMSM can be easily demagnetized. Therefore, it is important to study the demagnetization phenomenon of PMSMs for electric vehicles. However, since the demagnetization analysis procedure is complicated, previous studies have not been able to perform optimization considering demagnetization characteristics. In this study, we optimized the shape of a PMSM for electric vehicles by considering the demagnetization characteristics of permanent magnets using an automated design of experiments procedure. Using this procedure, a finite element analysis for each experimental point determined by a sampling method can be performed quickly and easily. The multi-objective function minimizes the demagnetization rate and maximizes the average torque, and the constraints are the efficiency and torque ripple. Various metamodels were generated for each of the multi-objective functions and constraints, and the metamodels with the best prediction performance were selected. By applying a multi-objective genetic algorithm, 1902 various optimal solutions were obtained. When the weight rate of the demagnetization rate to the torque was set to 0.1:0.9, the demagnetization rate and average torque were improved by 4.45% and 2.7%, respectively, compared to those of the initial model. The proposed multi-objective optimization method can guide the design of PMSMs for electric vehicles with high reliability and strong demagnetization characteristics.
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