Wentao Gao

In the optimization of high-speed permanent magnet motors (HSPMMs), electromagnetic characteristics, rotor stress, rotor dynamics, and temperature characteristics must all be considered simultaneously, and there are numerous optimization parameters for both the stator and rotor. These factors pose significant challenges to the multiphysics optimization of HSPMMs. Therefore, this paper presents a multiphysics optimization process for the HSPMM of 60 kW 30,000 rpm by combining subspace strategy and sequential strategy to mitigate the issues of high training volume and mutual coupling. Ten optimization parameters of stator and rotor are determined firstly. Then, using finite element analysis of rotor stress and rotor dynamics, the range of values for critical parameters of the rotor is established. Next, in the electromagnetic optimization, the process is divided into rotor parameter subspace and stator parameter subspace according to the subspace optimization strategy. The temperature field is also checked based on the optimization results. Finally, a prototype is manufactured and the comprehensive performance is tested to validate the multiphysics optimization process.

For outer rotor low-speed permanent magnet motors (LSPMMs), in the optimization design process, not only is the electromagnetic performance optimized, but the influence of the thermal load and copper loss on the temperature in the electromagnetic parameters should also be considered. However, these optimized designs that comprehensively consider electromagnetic performance and temperature characteristics are rare in the existing literature. Therefore, this paper focuses on a multi-objective optimization process considering efficiency, thermal load and copper loss. Firstly, according to the initial design, the influence of the design parameters on the efficiency and thermal load is analyzed, and the range of optimization parameters is determined. Next, the response surface is built, the response-surface analysis of electromagnetic performance is performed, and the parameter sensitivity is calculated. Then, the multi-objective optimization design is carried out by comprehensively considering the electromagnetic performance and temperature. Finally, compared with the initial scheme, the optimized scheme improves the efficiency and reduces the temperature, and the optimized scheme is verified by experimentation on a 22 kW, 56 rpm LSPMM prototype, which can provide a reference for the multi-objective optimization of LSPMMs by comprehensively considering the electromagnetic performance and temperature.

For high-speed permanent magnet machines (HSPMMs), many design schemes of rotor length–diameter ratios can satisfy the constraints of multiple physical fields during the motor design period. The rotor length–diameter ratio greatly impacts the comprehensive performances of multiple physical fields. However, these analyses are missing in the existing literature. Therefore, this paper focuses on the influence of the rotor length–diameter ratio on comprehensive performances. Firstly, finite element models (FEM) of multiple physical fields are built by ANSYS Workbench platform and Motor-CAD software. Then, the comprehensive performances of multiple physical fields are comparatively analyzed. Finally, the designed HSPMM is implemented, based on one prototype of 60 kW, 30,000 rpm to verify the results of comparative analysis. Based on the comparative analysis above, the influent laws of rotor length–diameter ratios on comprehensive performances of multiple physical fields are discussed and summarized, which can be used as a reference for the rotor structural design of HSPMMs.