Magnetic FEA Direct Optimization of High-Power Density, Halbach Array Permanent Magnet Electric Motors

Jean-Michel Grenier, Ramón Pérez, Mathieu Picard and Jérôme Cros
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Jean-Michel Grenier: LEEPCI, Department of Electrical and Computer Engineering, Laval University, 1065, Avenue de la Médecine, Quebec, QC G1V 0A6, Canada
Ramón Pérez: LEEPCI, Department of Electrical and Computer Engineering, Laval University, 1065, Avenue de la Médecine, Quebec, QC G1V 0A6, Canada
Mathieu Picard: CAMUS Laboratory, Université de Sherbrooke, 2500 Bld University, Sherbrooke, QC J1K 2R1, Canada
Jérôme Cros: LEEPCI, Department of Electrical and Computer Engineering, Laval University, 1065, Avenue de la Médecine, Quebec, QC G1V 0A6, Canada

Energies, 2021, vol. 14, issue 18, 1-19

Abstract: Hybrid electric aero-propulsion requires high power-density electric motors. The use of a constrained optimization method with the finite element analysis (FEA) is the best way to design these motors and to find the best solutions which maximize the power density. This makes it possible to take into account all the details of the geometry as well as the non-linear characteristics of magnetic materials, the conductive material and the current control strategy. Simulations were performed with a time stepping magnetodynamic solver while taking account the rotor movement and the stator winding was connected by an external electrical circuit. This study describes the magnetic FEA direct optimization approach for the design of Halbach array permanent magnet synchronous motors (PMSMs) and its advantages. An acceptable compromise between precision and computation time to estimate the electromagnetic torque, iron losses and eddy current losses was found. The finite element simulation was paired with analytical models to compute stress on the retaining sleeve, aerodynamic losses, and copper losses. This type of design procedure can be used to find the best machine configurations and establish design rules based on the specifications and materials selected. As an example, optimization results of PM motors minimizing total losses for a 150-kW application are presented for given speeds in the 2000 rpm to 50,000 rpm range. We compare different numbers of poles and power density between 5 kW/kg and 30 kW/kg. The choice of the number of poles is discussed in the function of the motor nominal speed and targeted power density as well as the compromise between iron losses and copper losses. In addition, the interest of having the current-control strategy as an optimization variable to generate a small amount of flux weakening is clearly shown.

Keywords: electrical motors; Halbach array; permanent magnet; high-power density; constrained optimization; finite element analysis (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: 2021
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (3)

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