This work presents a finite element analysis-based, topology optimization (TO) methodology for the combined magnetostatic and structural design of electrical machine cores. Our methodology uses the Bi-directional Evolutionary Structural Optimization (BESO) heuristics to remove inefficient elements from a meshed model based on elemental energies. The algorithm improves the average torque density while maintaining structural integrity. To the best of our knowledge, this work represents the first effort to address the structural-magnetostatic problem of electrical machine design using a free-form approach. Using a surface-mounted permanent magnet motor (PMM) as a case study, the methodology is first tested on linear and nonlinear two-dimensional problems whereby it is shown that the rapid convergence achieved makes the algorithm suitable for real-world applications. The proposed optimization scheme can be easily extended to three dimensions, and we propose that the resulting designs are suitable for manufacturing using selective laser melting, a 3D printing technology capable of producing fully dense high-silicon steel components with good soft magnetic properties. Three-dimensional TO results show that the weight of a PMM rotor can be slashed by 50% without affecting its rated torque profile when the actual magnetic permeability of the 3D-printed material is considered.
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July 2019
Research-Article
Free-Form Design of Electrical Machine Rotor Cores for Production Using Additive Manufacturing
Michele Garibaldi,
Michele Garibaldi
1
Centre for Additive Manufacturing (CfAM),
Nottingham NG7 2RD,
The University of Nottingham
,Nottingham NG7 2RD,
UK
;Power Electronics, Machines and Control Group (PEMC),
Nottingham NG7 2RD,
e-mail: michele.garibaldi@siemens.com
The University of Nottingham
,Nottingham NG7 2RD,
UK
e-mail: michele.garibaldi@siemens.com
1Corresponding author.
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Christopher Gerada,
Christopher Gerada
Power Electronics, Machines and Control Group (PEMC),
Nottingham NG7 2RD,
e-mail: chris.gerada@nottingham.ac.uk
The University of Nottingham
,Nottingham NG7 2RD,
UK
e-mail: chris.gerada@nottingham.ac.uk
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Ian Ashcroft,
Ian Ashcroft
Centre for Additive Manufacturing (CfAM),
Nottingham NG7 2RD,
e-mail: ian.ashcroft@nottingham.ac.uk
The University of Nottingham
,Nottingham NG7 2RD,
UK
e-mail: ian.ashcroft@nottingham.ac.uk
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Richard Hague
Richard Hague
Centre for Additive Manufacturing (CfAM),
Nottingham NG7 2RD,
e-mail: richard.hague@nottingham.ac.uk
The University of Nottingham
,Nottingham NG7 2RD,
UK
e-mail: richard.hague@nottingham.ac.uk
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Michele Garibaldi
Centre for Additive Manufacturing (CfAM),
Nottingham NG7 2RD,
The University of Nottingham
,Nottingham NG7 2RD,
UK
;Power Electronics, Machines and Control Group (PEMC),
Nottingham NG7 2RD,
e-mail: michele.garibaldi@siemens.com
The University of Nottingham
,Nottingham NG7 2RD,
UK
e-mail: michele.garibaldi@siemens.com
Christopher Gerada
Power Electronics, Machines and Control Group (PEMC),
Nottingham NG7 2RD,
e-mail: chris.gerada@nottingham.ac.uk
The University of Nottingham
,Nottingham NG7 2RD,
UK
e-mail: chris.gerada@nottingham.ac.uk
Ian Ashcroft
Centre for Additive Manufacturing (CfAM),
Nottingham NG7 2RD,
e-mail: ian.ashcroft@nottingham.ac.uk
The University of Nottingham
,Nottingham NG7 2RD,
UK
e-mail: ian.ashcroft@nottingham.ac.uk
Richard Hague
Centre for Additive Manufacturing (CfAM),
Nottingham NG7 2RD,
e-mail: richard.hague@nottingham.ac.uk
The University of Nottingham
,Nottingham NG7 2RD,
UK
e-mail: richard.hague@nottingham.ac.uk
1Corresponding author.
Contributed by the Design Automation Committee of ASME for publication in the Journal of Mechanical Design. Manuscript received August 3, 2018; final manuscript received December 23, 2018; published online March 13, 2019. Assoc. Editor: Samy Missoum.
J. Mech. Des. Jul 2019, 141(7): 071401 (13 pages)
Published Online: March 13, 2019
Article history
Received:
August 3, 2018
Revision Received:
December 23, 2018
Accepted:
January 1, 2019
Citation
Garibaldi, M., Gerada, C., Ashcroft, I., and Hague, R. (March 13, 2019). "Free-Form Design of Electrical Machine Rotor Cores for Production Using Additive Manufacturing." ASME. J. Mech. Des. July 2019; 141(7): 071401. https://doi.org/10.1115/1.4042621
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