Design of Electromagnetic Actuators Using Layout Optimization With Distributed Current Source Models


This paper presents a layout optimization technique for maximizing the torque-to-weight ratio of an electromagnetic actuator. Layout optimization, which focuses on finding practical designs to maximize output performance during a compact style, avoids nonlinearity and native convergence issues in the optimization of the electromagnetic system using 2 sequential steps; linear topology optimization and integer programming. Formulated in terms of decomposed volume and surface parts with equivalent current sources, the linear topology optimization optimizes the permanent magnet material distribution in the rotor. With the linearly optimized styles, integer programming determines the “most preferred” style in the second step by evaluating performances over design complexity. As illustrations, the strategy is applied to maximise the torque performance of two completely different three-section disk-formed synchronous motors. The effects of 2 different current waveforms, sinusoidal and square wave, on the torque magnitude and ripple are thought of within the optimization. The planning method has been experimentally validated by comparing simulated results of the layout optimization with measured magnetic field and torque output. This element-wise method that maximizes the online force/torque averaged over varied orientations represents an improvement over existing algorithms where topology optimization is conducted at a specific rotor orientation to cut back the computational price.

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