Overview
A balance between material costs and efficiency, durability, and performance is critical in motor design and development. Expensive low-loss materials lead to highly efficient motors but increase product costs. However, in addition to reducing losses, strength and weight are also essential considerations for certain parts. Engineers can use a single optimization in JMAG to evaluate the trade-offs between the material costs and performance.
This case study runs a multi-objective geometry and material optimization of an IPM motor to minimize the iron losses and material costs. The material optimization evaluates nine combinations of three different materials for the rotor and stator cores. The results indicate that a rotor core made of electromagnetic steel sheet and a stator core that uses amorphous or nanocrystalline alloy as a low-loss material best balances lower iron losses against the material costs.
IPM Motor
Optimization Conditions
| Design variables (materials) |
Stator core and rotor core: Electromagnetic steel sheel, amorphous alloy, and nanocrystalline alloy |
| Objective functions | Minimize iron losses/ minimize material costs |
| Constraint conditions | Average torque: 150 Nm or higher |
Fig. 1 Analysis Model and Optimization Conditions
This case study runs a geometry and material optimization of an IPM motor. As illustrated by the table on the right, the optimization uses nine different combinations of three materials for the rotor and stator cores to evaluate the trade-offs between the iron losses and material costs.
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