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Topology Optimization for Generating Optimal Free-Form Rotor Structures in PMSMs
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DOI：10.1109/TEC.2025.3646612.png)
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Abstract
En 中文
To achieve high performance in the rotor design of permanent magnet synchronous motors(PMSMs), it is essential to optimally arrange materials and magnetic flux paths from a structural design perspective. This paper proposes a multi-material topology optimization(MMTO)approach, based on the Solid Isotropic Material with Penalization(SIMP)method, to automatically generate optimal PMSM rotor structures with high design freedom. The proposed method employs a multi-material interpolation technique to represent the spatial distribution of ferromagnetic materials, permanent magnets (PMs), and air, while comprehensively considering electromagnetic and mechanical performance. In addition, the magnetization and current angles are independently optimized to maximize output performance. An optimization framework is established using the Augmented Lagrangian method, with sensitivities of the design variables derived. A variable filter-radius strategy is introduced to ensure effective convergence of the optimization process. Compared with classical parameter optimization based on heuristic methods, the proposed method achieves superior PMSM designs. Experimental validation confirms its effectiveness.
Keywords:
Design methodology
finite element analysis
permanent magnet machines
smart manufacturing
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