Topology Optimization for the Manufacturable and Structurally Safe Synchronous Reluctance Motors with Multiple Iron Webs and Bridges

Abstract

The goal of this article is to develop a new topology optimization framework that can secure the manufacturability of the synchronous reluctance motors (SynRMs) with multiple iron webs and bridges while satisfying the required electromagnetic and mechanical performances. In the SynRM, multiple iron webs and bridges are crucial to achieve a higher torque and a structural safety. A minimum thickness of the web and bridge should also be guaranteed to achieve manufacturability. To acquire the optimal SynRM that can satisfy the above characteristics, a two-stage topology optimization framework is proposed with an individual filtering-and-penalization scheme. This proposed scheme can individually control the number and thickness of multiple iron webs and bridges in the rotor to obtain the manufacturable and structurally safe SynRMs. For the abovementioned purpose, topology optimization is formulated to minimize a torque ripple while satisfying the desired average torque, structural compliance, and a rotational moment of inertia. Average torque and structural compliance are evaluated by performing the electromagnetic and structural finite element analyses, respectively, at each iteration of topology optimization. Here, design-dependent loads are considered in the radial and circumferential directions to reflect a high-speed rotation. Through investigating the optimized SynRM designs with various filter radii, the relationship among the torque, structural pattern, and stress distribution is examined. Finally, the experimental results with the manufactured prototypes validate the feasibility and potential of the proposed design method.