Robust Design of a Low-Cost Permanent Magnet Motor with Soft Magnetic Composite Cores Considering the Manufacturing Process and Tolerances
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...
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MDPI AG
2018-08-01
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| Series: | Energies |
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| Online Access: | http://www.mdpi.com/1996-1073/11/8/2025 |
| _version_ | 1798038953481207808 |
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| author | Chengcheng Liu Gang Lei Bo Ma Youguang Guo Jianguo Zhu |
| author_facet | Chengcheng Liu Gang Lei Bo Ma Youguang Guo Jianguo Zhu |
| author_sort | Chengcheng Liu |
| collection | DOAJ |
| description | 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. |
| first_indexed | 2024-04-11T21:47:18Z |
| format | Article |
| id | doaj.art-fe60e1d8f0394af09e40174750fbfa3f |
| institution | Directory Open Access Journal |
| issn | 1996-1073 |
| language | English |
| last_indexed | 2024-04-11T21:47:18Z |
| publishDate | 2018-08-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Energies |
| spelling | doaj.art-fe60e1d8f0394af09e40174750fbfa3f2022-12-22T04:01:23ZengMDPI AGEnergies1996-10732018-08-01118202510.3390/en11082025en11082025Robust Design of a Low-Cost Permanent Magnet Motor with Soft Magnetic Composite Cores Considering the Manufacturing Process and TolerancesChengcheng Liu0Gang Lei1Bo Ma2Youguang Guo3Jianguo Zhu4School of Electrical and Electronic Engineering, Huazhong University of Science and Technology, Wuhan 430074, ChinaSchool of Electrical and Data Engineering, University of Technology Sydney, Sydney, NSW 2007, AustraliaSchool of Electrical and Data Engineering, University of Technology Sydney, Sydney, NSW 2007, AustraliaSchool of Electrical and Data Engineering, University of Technology Sydney, Sydney, NSW 2007, AustraliaSchool of Electrical and Information Engineering, The University of Sydney, Sydney, NSW 2000, AustraliaThis 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.http://www.mdpi.com/1996-1073/11/8/2025permanent magnet motorsoft magnetic compositeTaguchi methodmanufacturing tolerances |
| spellingShingle | Chengcheng Liu Gang Lei Bo Ma Youguang Guo Jianguo Zhu Robust Design of a Low-Cost Permanent Magnet Motor with Soft Magnetic Composite Cores Considering the Manufacturing Process and Tolerances Energies permanent magnet motor soft magnetic composite Taguchi method manufacturing tolerances |
| title | Robust Design of a Low-Cost Permanent Magnet Motor with Soft Magnetic Composite Cores Considering the Manufacturing Process and Tolerances |
| title_full | Robust Design of a Low-Cost Permanent Magnet Motor with Soft Magnetic Composite Cores Considering the Manufacturing Process and Tolerances |
| title_fullStr | Robust Design of a Low-Cost Permanent Magnet Motor with Soft Magnetic Composite Cores Considering the Manufacturing Process and Tolerances |
| title_full_unstemmed | Robust Design of a Low-Cost Permanent Magnet Motor with Soft Magnetic Composite Cores Considering the Manufacturing Process and Tolerances |
| title_short | Robust Design of a Low-Cost Permanent Magnet Motor with Soft Magnetic Composite Cores Considering the Manufacturing Process and Tolerances |
| title_sort | robust design of a low cost permanent magnet motor with soft magnetic composite cores considering the manufacturing process and tolerances |
| topic | permanent magnet motor soft magnetic composite Taguchi method manufacturing tolerances |
| url | http://www.mdpi.com/1996-1073/11/8/2025 |
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