Optimization of Three-Phase Hybrid Stepper Motors for Noise Reduction

Abstract

For the optimization of three-phase hybrid stepper motors with complex electromagnetic structures, an optimization method is presented in this paper. The method is a combination of 3D-FEM and the Taguchi optimization method intended to reduce the dependence on FEM results during the optimization calculation. In this paper, the optimization method is used in the optimization of the tooth shape of the three-phase hybrid stepper motor, and the objective is to reduce the noise caused by harmonics in the “torque-angle characteristic” of the motor. It is clear that traditional optimization methods make it very difficult to carry out such an optimization calculation as a large number of finite element calculations have to be used in the optimization process, and the required computation time is extremely long. Using the optimization method presented in the paper, the optimization becomes feasible because the number of finite element calculations is greatly reduced and the computation time is thus greatly reduced. In order to check the effectiveness of the optimization, the waterfall diagram for noise analysis and its application to check torque ripple are also presented in the paper. Both simulation and test results show that the optimized structure can significantly reduce the motor noise caused by torque ripple. Therefore, the optimization method proposed in this paper can be an effective tool for the optimal design of high-performance motors, including stepper motors.

Contribution to the Full 3D Finite Element Modelling of a Hybrid Stepping Motor with and without Current in the Coils

“…This map (Figure 10) shows lines corresponding to the axial and radial components of the magnetic flux. The axial flow of the flux is of purely reluctant origin [7] [8] [12] whereas the radial magnetic flux is induced by the coils of the phase supplied with electric current. The coexistence of these two sources in this machine makes it impossible to study them analytically and even numerically in 2D since they cannot take into account the axial components of the magnetic flux.…”

Measurement of Magnetic and Magnetostrictive Characteristics of Transformer Core Based on Triaxial Strain Gauge and B-H Vector Sensor

“…Scholars have conducted extensive research on the vibration and noise of motors and transformers. Peng et al applied an optimization algorithm combined with the 3D FEM and Taguchi optimization method to the tooth shape of the three-phase hybrid stepper motor to reduce the noise caused by harmonics in the "torque-angle characteristics" of the motor [5]. Hu et al analyzed the critical vibration suppression of the maglev high-speed motor with µ-synthesis control [6].…”