Search results

(1 - 1 of 1)

Title

TOPOLOGY OPTIMIZATION OF SYNCHRONOUS ELECTRIC MACHINES

Creator

Guo, Feng

Date

2021

Description

Topology optimization of electric machine is attractive because of the increased design degree of freedom compared to conventional electric...
Show moreTopology optimization of electric machine is attractive because of the increased design degree of freedom compared to conventional electric machine design techniques. Also, a topology optimization approach does not necessarily require the use of a geometric template where dimensions are controlled by parameters. In this dissertation, a density-based magneto-structural topology optimization approach for the design of synchronous reluctance machine (SynRel), interior permanent magnet synchronous machine (IPMSM), and wound field synchronous machine (WFSM) rotors is developed. Depending on the electric machine type, the optimization problems are divided into single material and multi-material topology optimizations. A mass thresholding function is introduced to overcome the intermediate density issue which is caused by combining the magnetic and structural topology optimization problems. SynRel and IPMSM optimization examples are presented in the single material topology optimization section. For the multi-material topology optimization, in order to properly define the boundary conditions between multiple materials, a virtual region calculation approach is proposed. In the WFSM topology optimization, the copper field winding is represented by a virtual region. The contact and frictionless boundary conditions between the copper field winding and the electrical steel is defined and the centripetal load of the copper winding are equivalently calculated and applied on the elements on the electrical steel next to the boundary between the copper field winding and the steel of the WFSM pole tip. In additional to the total free-form magneto-structural topology optimization, a density-based combined dimensional and topology optimization is developed for the design of IPMSM and WFSM rotors. Both the dimensional and topological control variables are integrated to simplify the optimization problem. For IPMSM rotor design, the permanent magnet (PM) block shape is preferred to be retained where dimensional optimization could be used. The proposed dimensional topology optimization approach can fit in this design situation, where the PM is designed using dimensional control variables where the rest of the design domain is optimized using topology optimization. To allow the block or rectangular magnet to move and change size, the surrounding design domain mesh must deform or distort. The Laplace's smoothing mesh deformation technique is used in this approach and helper lines are connected to allow greater mesh deformation range and to avoid over mesh distortion. In addition to IPMSMs, a WFSM example is presented optimizing the winding region using dimensional optimization and the rotor core using topology optimization. An alternative combined dimensional and topology optimization approach has also been developed primarily for the design of the IPMSM rotors. In this approach, the mesh deformation is not required but there is no explicit geometric boundary between the rectangular permanent magnet and the surrounding electrical steel and air. In this approach, the PM density is expressed as a Heaviside rectangular function of dimensional variables. The function is projected onto the rotor mesh. Modified material penalizations are used. Topology optimization then controls the deposition of electrical steel and air. Three different IPMSM examples are presented with different dimensional control variables, including the PM position, size and angle.
Show less