Reliability-Based Robust Design Optimization for Maximizing the Output Torque of Brushless Direct Current (BLDC) Motors Considering Manufacturing Uncertainty

In recent years, the deterministic design optimization method has been widely used to improve the output performance of brushless direct current (BLDC) motors. However, it does not contribute to reducing the failure rate and performance variation of products because it cannot determine the manufactu...

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Main Authors: Kyunghun Jeon, Donghyeon Yoo, Jongjin Park, Ki-Deok Lee, Jeong-Jong Lee, Chang-Wan Kim
Format: Article
Language:English
Published: MDPI AG 2022-09-01
Series:Machines
Subjects:
Online Access:https://www.mdpi.com/2075-1702/10/9/797
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author Kyunghun Jeon
Donghyeon Yoo
Jongjin Park
Ki-Deok Lee
Jeong-Jong Lee
Chang-Wan Kim
author_facet Kyunghun Jeon
Donghyeon Yoo
Jongjin Park
Ki-Deok Lee
Jeong-Jong Lee
Chang-Wan Kim
author_sort Kyunghun Jeon
collection DOAJ
description In recent years, the deterministic design optimization method has been widely used to improve the output performance of brushless direct current (BLDC) motors. However, it does not contribute to reducing the failure rate and performance variation of products because it cannot determine the manufacturing uncertainty. In this study, we proposed reliability-based robust design optimization to improve the output torque of a BLDC motor while reducing the failure rate and performance variation. We calculated the output torque and vibration response of the BLDC motor using the electromagnetic–structural coupled analysis. We selected the tooth thickness, slot opening width, slot radius, slot depth, tooth width, magnet thickness, and magnet length as the design variables related to the shape of the stator and rotor that affect the output torque. We considered the distribution of design variables with manufacturing tolerances. We performed a reliability analysis of the BLDC motor considering the distribution of design variables with manufacturing tolerances. Using the reliability analysis results, we performed reliability-based robust design optimization (RBRDO) to maximize the output torque; consequently, the output torque increased by 8.8% compared to the initial BLDC motor, the standard deviation in output performance decreased by 46.9% with improved robustness, and the failure rate decreased by 99.2% with enhanced reliability. The proposed reliability-based robust design optimization is considered to be useful in the actual product design field because it can evaluate both the reliability and robustness of the product and improve its performance in the design stage.
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spelling doaj.art-23b125ea9020409ebf858983aec4798e2023-11-23T17:27:03ZengMDPI AGMachines2075-17022022-09-0110979710.3390/machines10090797Reliability-Based Robust Design Optimization for Maximizing the Output Torque of Brushless Direct Current (BLDC) Motors Considering Manufacturing UncertaintyKyunghun Jeon0Donghyeon Yoo1Jongjin Park2Ki-Deok Lee3Jeong-Jong Lee4Chang-Wan Kim5Graduate School of Mechanical Design & Production Engineering, Konkuk University, 120 Neungdong-ro, Gwangjin-gu, Seoul 05029, KoreaGraduate School of Mechanical Design & Production Engineering, Konkuk University, 120 Neungdong-ro, Gwangjin-gu, Seoul 05029, KoreaGraduate School of Mechanical Design & Production Engineering, Konkuk University, 120 Neungdong-ro, Gwangjin-gu, Seoul 05029, KoreaIntelligent Mechatronics Research Center, Korea Electronics Technology Institute, Seongnam-si 13509, Gyeonggi-do, KoreaIntelligent Mechatronics Research Center, Korea Electronics Technology Institute, Seongnam-si 13509, Gyeonggi-do, KoreaSchool of Mechanical Engineering, Konkuk University, 120 Neungdong-ro, Gwangjin-gu, Seoul 05029, KoreaIn recent years, the deterministic design optimization method has been widely used to improve the output performance of brushless direct current (BLDC) motors. However, it does not contribute to reducing the failure rate and performance variation of products because it cannot determine the manufacturing uncertainty. In this study, we proposed reliability-based robust design optimization to improve the output torque of a BLDC motor while reducing the failure rate and performance variation. We calculated the output torque and vibration response of the BLDC motor using the electromagnetic–structural coupled analysis. We selected the tooth thickness, slot opening width, slot radius, slot depth, tooth width, magnet thickness, and magnet length as the design variables related to the shape of the stator and rotor that affect the output torque. We considered the distribution of design variables with manufacturing tolerances. We performed a reliability analysis of the BLDC motor considering the distribution of design variables with manufacturing tolerances. Using the reliability analysis results, we performed reliability-based robust design optimization (RBRDO) to maximize the output torque; consequently, the output torque increased by 8.8% compared to the initial BLDC motor, the standard deviation in output performance decreased by 46.9% with improved robustness, and the failure rate decreased by 99.2% with enhanced reliability. The proposed reliability-based robust design optimization is considered to be useful in the actual product design field because it can evaluate both the reliability and robustness of the product and improve its performance in the design stage.https://www.mdpi.com/2075-1702/10/9/797brushless direct current motormanufacturing uncertaintyreliability-based robust design optimizationoutput torquetorque ripplevibration analysis
spellingShingle Kyunghun Jeon
Donghyeon Yoo
Jongjin Park
Ki-Deok Lee
Jeong-Jong Lee
Chang-Wan Kim
Reliability-Based Robust Design Optimization for Maximizing the Output Torque of Brushless Direct Current (BLDC) Motors Considering Manufacturing Uncertainty
Machines
brushless direct current motor
manufacturing uncertainty
reliability-based robust design optimization
output torque
torque ripple
vibration analysis
title Reliability-Based Robust Design Optimization for Maximizing the Output Torque of Brushless Direct Current (BLDC) Motors Considering Manufacturing Uncertainty
title_full Reliability-Based Robust Design Optimization for Maximizing the Output Torque of Brushless Direct Current (BLDC) Motors Considering Manufacturing Uncertainty
title_fullStr Reliability-Based Robust Design Optimization for Maximizing the Output Torque of Brushless Direct Current (BLDC) Motors Considering Manufacturing Uncertainty
title_full_unstemmed Reliability-Based Robust Design Optimization for Maximizing the Output Torque of Brushless Direct Current (BLDC) Motors Considering Manufacturing Uncertainty
title_short Reliability-Based Robust Design Optimization for Maximizing the Output Torque of Brushless Direct Current (BLDC) Motors Considering Manufacturing Uncertainty
title_sort reliability based robust design optimization for maximizing the output torque of brushless direct current bldc motors considering manufacturing uncertainty
topic brushless direct current motor
manufacturing uncertainty
reliability-based robust design optimization
output torque
torque ripple
vibration analysis
url https://www.mdpi.com/2075-1702/10/9/797
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