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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Combined Dimensional and Topology Optimization of Synchronous Machine Rotors Using a Material Density Interpolation Method

This article presents a magneto-structural combined dimensional and topology optimization technique for interior permanent magnet synchronous machine (IPMSM) and wound field synchronous machine (WFSM) rotors. Dimensional changes to the permanent magnet (PM) and rotor winding location or size are accomplished by interpolating or projecting a smoothed Heaviside rectangular function representing the presence of PM material onto the IPMSM rotor design domain mesh, whereas the presence of copper material for WFSM rotor is interpolated in the same manner. A density based Solid Isotropic Material with Penalization (SIMP) topology optimization approach is then used to vary the presence of electrical steel in mesh elements to form flux barriers around the PM. The proposed method enforces a defined shape for the PM without requiring the mesh in the design domain to be deformed. Four examples are presented to demonstrate the technique: Two flat bar IPMSM, one V-shaped IPMSM, and a WFSM. Here, a comparative study is performed on one of the flat bar IPMSMs using Metamodel of Optimal Prognosis (MOP) based method.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Combined Dimensional and Topology Optimization of Interior Permanent Magnet Synchronous Machine Rotors Using a Permanent Magnet Function Interpolation Method

This paper presents a magneto-structural combined dimensional and topology optimization technique for interior permanent magnet synchronous machine (IPMSM) rotors. Dimensional changes to the permanent magnet (PM) location or size are accomplished by interpolating or projecting a smoothed Heaviside rectangular function representing the presence of PM material onto the IPMSM rotor design domain mesh. A density based Solid Isotropic with Material Penalization (SIMP) topology optimization approach is then used to vary the presence of electrical steel in mesh elements to form flux barriers around the PM. The proposed method enforces a defined shape for the PM without requiring the mesh in the design domain to be deformed. Three examples are presented to demonstrate the technique: two flat bar IPMSM and one V-shaped IPMSM.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Magneto-Structural Combined Dimensional and Topology Optimization of Interior Permanent Magnet Synchronous Machine Rotors

A magneto-structural combined dimensional and topology optimization approach for interior permanent magnet synchronous machine (IPMSM) rotor design is proposed using the Solid Isotropic Material Penalization (SIMP) density-based topology optimization method. This method optimizes the location and dimensions of the permanent magnets (PMs) embedded in the rotor, while simultaneously optimizing the lamination flux barriers using topology optimization.To allow for the location and dimensions of the PMs to change while retaining the same number of mesh elements and connectivity, the mesh must be deformed. Mesh deformation is accomplished using a Laplace smoothing technique. To increase the range of PM displacement and size changes, the non-PM areas of the rotor design domain are divided into sub-regions along whose boundaries the mesh nodes are redistributed also using a Laplace smoothing algorithm. Three examples of IPMSM rotor optimizations are presented to demonstrate the proposed approach.

33 ADVANCED PROPULSION SYSTEMS↗