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Robust Design of a Low-Cost Permanent Magnet Motor with Soft Magnetic Composite Cores Considering the Manufacturing Process and Tolerances

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  • Chengcheng Liu

    (School of Electrical and Electronic Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
    State Key Laboratory of Reliability and Intelligence of Electrical Equipment, Hebei University of Technology, Tianjin 300130, China)

  • Gang Lei

    (School of Electrical and Data Engineering, University of Technology Sydney, Sydney, NSW 2007, Australia)

  • Bo Ma

    (School of Electrical and Data Engineering, University of Technology Sydney, Sydney, NSW 2007, Australia)

  • Youguang Guo

    (School of Electrical and Data Engineering, University of Technology Sydney, Sydney, NSW 2007, Australia)

  • Jianguo Zhu

    (School of Electrical and Information Engineering, The University of Sydney, Sydney, NSW 2000, Australia)

Abstract

This paper uses the Taguchi method to optimize the manufacturing process and robust design of a low-cost permanent magnet motor with soft magnetic composite (SMC) cores. For the manufacturing process, SMC cores are produced by using the molding technology without any wire cutting costs. To maximize the relative permeability and minimize the core loss, the Taguchi method is employed to identify the best control factor values for the heat treatment of SMC cores based on a series of experimental results. Due to the manufacturing tolerances, there are significant uncertainties in the core densities and motor dimensions, which will result in big performance variations for the SMC motors in the batch production. To obtain a robust design less sensitive to these tolerances, the conventional Taguchi parameter design method and a sequential Taguchi optimization method are presented to maximize the average torque and minimize the core loss of a low-cost PM motor. Through comparison, it is found that the proposed optimization method is efficient. It can provide an optimal design with better motor performance and manufacturing quality. The proposed method will benefit the industrial production of cost-effective PM-SMC motors with robust and compact designs.

Suggested Citation

  • Chengcheng Liu & Gang Lei & Bo Ma & Youguang Guo & Jianguo Zhu, 2018. "Robust Design of a Low-Cost Permanent Magnet Motor with Soft Magnetic Composite Cores Considering the Manufacturing Process and Tolerances," Energies, MDPI, vol. 11(8), pages 1-17, August.
    • Handle: RePEc:gam:jeners:v:11:y:2018:i:8:p:2025-:d:161872
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    References listed on IDEAS

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    1. Gang Lei & Jianguo Zhu & Youguang Guo & Chengcheng Liu & Bo Ma, 2017. "A Review of Design Optimization Methods for Electrical Machines," Energies, MDPI, vol. 10(12), pages 1-31, November.
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    Cited by:

    1. 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.
    2. Da-Chen Pang & Zhen-Jia Shi & Pei-Xuan Xie & Hua-Chih Huang & Gia-Thinh Bui, 2020. "Investigation of an Inset Micro Permanent Magnet Synchronous Motor Using Soft Magnetic Composite Material," Energies, MDPI, vol. 13(17), pages 1-11, August.

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