Optimal Rotor Design for Reducing Electromagnetic Vibration in Traction Motors Based on Numerical Analysis

Interior permanent magnet synchronous motor (IPMSM) for traction applications have attracted significant attention due to their advantages of high torque and power density as well as a wide operating range. However, these motors suffer from high electromagnetic vibration noise due to their complex structure and structural rigidity. The main sources of this electromagnetic vibration noise are cogging torque, torque ripple, and radial force. To predict electromagnetic vibration noise, finite element analysis (FEA) with flux density analysis of the air gap is essential. This approach allows for the calculation of radial force that is the source of the vibration and enables the prediction of vibration in advance. The data obtained from these analyses provide important guidance for reducing vibration and noise in the design of electric motors. In this paper, the cogging torque and vibration at rated and maximum operating speed are analyzed, and an optimal cogging torque and vibration reduction model, with rotor taper and two-step skew structure, is proposed using the response surface method (RSM) to minimize them. The validity of the proposed model is demonstrated through formulations and FEA based entirely on numerical analysis and results. This study is expected to contribute to the design of more efficient and quieter electric motors by providing a solution to the electromagnetic vibration noise problem generated by IPMSM for traction applications with complex structures.