Topology Optimization to Reduce Electromagnetic Force Induced Vibration for the Specific Frequency of PMSM Motor Using Electromagnetic-Structural Coupled Analysis

Abstract

Vibration and noise reduction are very important in electric vehicle driving motors. In this study, topology optimization of housing was performed to reduce vibration in a specific frequency caused by electromagnetic force generated by a permanent magnet synchronous motor (PMSM). The vibration induced by the electromagnetic force of the motor was calculated using electromagnetic-structural coupled analysis. Then, the magnitude of the acceleration for a specific frequency at which peak occurs in the rectangular and circular shape housing concept design model was reduced by using the topology optimization method. As a result, the rectangular and circular shape housing design reduced 92.9% and 96.0%, respectively. Finally, the vibration was effectively reduced while maintaining the electromagnetic characteristics of the motor, for which topology optimization was conducted while not changing the rotor or stator shape design (electromagnetic design factor) but by changing the motor housing shape design (mechanical and structural design factor).

Topology Optimization for Electromagnetics: A Survey

“…Firstly introduced by Bendsøe and Kikuchi in 1988 [1], the homogenization method, was applied to a variety of structural topology optimization problems [69] and, with less impact, to the design of electromagnetic devices [28], [29], [70], [71].…”

Noise and vibration modelling of Permanent Magnet Synchronous Motors - a review

“…When the modes are known, it is possible to apply electromagnetic force directly on the tooth head and thus simulate motor vibrations during an operating cycle [11], [21], [88], [116], [117], as described below (see section V-C3). Numerical eigenfrequencies and eigenmodes can be compared with experimental Frequency Response Function (FRF) derived from hammer test [118].…”

Numerical Simulation of Lost-Foam Casting for Key Components of A356 Aluminum Alloy in New Energy Vehicles

“…(3) The foam undergoes direct decomposition from a solid to a gaseous state without any intermediate states. (4) The flow of melt is assumed to be laminar since the overall filling velocities are slow, resulting in a low Reynolds number.…”

“…Aluminum alloys have received widespread attention in the aerospace and vehicle weight reduction fields due to their low density and excellent corrosion resistance properties [2]. The aluminum alloy motor housing serves as a core casting in the powertrain of new energy vehicles [3,4]. Its top and bottom parts are respectively connected to the inverter and the reducer, and it connects to the vehicle's main shaft bearings through bearing liners.…”