Robust Design of a Low-Cost Permanent Magnet Motor with Soft Magnetic Composite Cores Considering the Manufacturing Process and Tolerances

Chengcheng Liu, Gang Lei, Bo Ma, Youguang Guo and Jianguo Zhu
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Chengcheng Liu: School of Electrical and Electronic Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
Gang Lei: School of Electrical and Data Engineering, University of Technology Sydney, Sydney, NSW 2007, Australia
Bo Ma: School of Electrical and Data Engineering, University of Technology Sydney, Sydney, NSW 2007, Australia
Youguang Guo: School of Electrical and Data Engineering, University of Technology Sydney, Sydney, NSW 2007, Australia
Jianguo Zhu: School of Electrical and Information Engineering, The University of Sydney, Sydney, NSW 2000, Australia

Energies, 2018, vol. 11, issue 8, 1-17

Abstract: 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.

Keywords: permanent magnet motor; soft magnetic composite; Taguchi method; manufacturing tolerances (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2018
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (2)

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