A Multi-Physics Design Approach for Electromagnetic and Stress
Performance Improvement in an Interior Permanent Magnet Motor
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abstract
<div>Electric motors constitute a critical component of an electric vehicle
powertrain. An improved motor design can help improve the overall performance of
the drivetrain of an electric vehicle making it more compact and power dense. In
this article, the electromagnetic torque output of a double V-shaped traction
IPMSM is maximized by geometry optimization, while considering overall material
cost minimization as the second objective. A robust and flexible parametric
model of the IPMSM is developed in ANSYS Maxwell 2D. Various parameters are
defined in the rotor and stator geometries to perform an effective
multi-objective parametric design optimization. Advanced sensitivity analysis,
surrogate modeling, and optimization capabilities of ANSYS optiSlang software
are leveraged in the optimization. Furthermore, a demagnetization analysis is
performed to evaluate the robustness of the optimized design. At high-speed
operation, a rotor core is usually subject to higher deformation due to the high
centrifugal force. Thus, rotor stresses are reduced in the optimized design by
shaping the flux barriers around the permanent magnets. This enables high
structural integrity of the optimized design for high-speed operation along with
the improved electromagnetic performance. The multi-physics design approach
proposed in this article provides the capability to design and optimize an IPMSM
geometry for performance and cost, which are essential objectives to achieve in
an electrified powertrain development. Moreover, consideration of rotor stress
at high operating speeds extends the applicability of the proposed design
approach to high-power, high-speed electric propulsion applications.</div>
