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Tolerance Sensitivity Analysis and Robust Optimal Design Method of a Surface-Mounted Permanent Magnet Motor by Using a Hybrid Response Surface Method Considering Manufacturing Tolerances

Author

Listed:
  • Cha-Seung Jun

    (Appliance R & D Laboratory, LG Electronics Inc., Seoul 08592, Korea)

  • Byung-Il Kwon

    (Department of Electronic Systems Engineering, Hanyang University, Ansan 15588, Korea)

  • Ohbong Kwon

    (New York City College of Technology, New York 11201, NY, USA)

Abstract

This paper presents a robust optimal design method using a hybrid response surface method (H-RSM) which directly finds an optimal point satisfying a target Z-value or a probability of failure. Through three steps, this paper achieves the goal that is to increase the open-circuit airgap flux (OCAF) in a surface-mounted permanent magnet motor and decrease its variation caused by variations of the airgap lengths including an additional one between permanent magnets and rotor back yoke. First, the OCAF equation is derived from the magnetic equivalent circuit (MEC) considering the additional airgap. Then, the equation is validated by comparing its results with those of the finite element method (FEM) modeled by the slotless stator. Next, the tolerance sensitivity analysis, using the partial derivative of the OCAF equation with respect to the airgap length, is performed to investigate the effects of design variables on the OCAF. It is shown that increasing the magnet thickness is effective for both increasing mean of the OCAF and reducing its variation. Finally, robust optimal design is performed using the H-RSM, in which all data are obtained from the FEM modeled by the slotted stator. The results of the robust optimal design are verified using the FEM.

Suggested Citation

  • Cha-Seung Jun & Byung-Il Kwon & Ohbong Kwon, 2018. "Tolerance Sensitivity Analysis and Robust Optimal Design Method of a Surface-Mounted Permanent Magnet Motor by Using a Hybrid Response Surface Method Considering Manufacturing Tolerances," Energies, MDPI, vol. 11(5), pages 1-16, May.
    • Handle: RePEc:gam:jeners:v:11:y:2018:i:5:p:1159-:d:144808
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    References listed on IDEAS

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    1. Zhen Tian & Chengning Zhang & Shuo Zhang, 2017. "Analytical Calculation of Magnetic Field Distribution and Stator Iron Losses for Surface-Mounted Permanent Magnet Synchronous Machines," Energies, MDPI, vol. 10(3), pages 1-12, March.
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    Cited by:

    1. Nusrat Rezwana Shahreen Popsi & Animesh Anik & Rajeev Verma & Caniggia Viana & K. Lakshmi Varaha Iyer & Narayan C. Kar, 2024. "Influence of Electric Motor Manufacturing Tolerances on End-of-Line Testing: A Review," Energies, MDPI, vol. 17(8), pages 1-12, April.
    2. Keun-Young Yoon & Soo-Whang Baek, 2019. "Robust Design Optimization with Penalty Function for Electric Oil Pumps with BLDC Motors," Energies, MDPI, vol. 12(1), pages 1-14, January.

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