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1.3 The State-of-Art Design Optimization Methods 17
1.3 The State-of-Art Design Optimization Methods 17
17
shaft, acceleration of abrasion, which shortens signicantly the lifetime of the motor
and drive system.
The assembly of stator cores can also be a big challenge for SMC motors. For
manufacturing convenience, the stator core of an SMC motor is often molded in
separate pieces. Any extra air gap between two pieces of the stator core caused by
poor assembly process will result in large reduction of air gap ux density and in
turn the motor efciency. Good assembly structures should be investigated in the
design stage of SMC motors.
Figure 1.13 illustrates a multi-disciplinary design framework of electrical motors
and drive systems that we propose to take into account the manufacturing quality in
mass production in the design stage. The rst step is to dene the acceptable
maximal defect-ratio and system performance. Under these specications, the
motor types, topologies, materials, inverters, and controllers will be designed and
optimized under the multi-disciplinary design and machinery technology design.
Due to these manufacturing tolerances, the design optimization of electrical
drive systems for mass production is really a challenge in both research and
industrial communities as it includes not only the theoretical multi-disciplinary
design and analysis but also the practical engineering manufacturing of electrical
machines and drive systems. Meanwhile, many new control algorithms, e.g. MPC,
have been proposed for motor control, and in the design optimization stage, various
many algorithm parameters should be optimized for the best drive system dynamic
performance. From the industrial application perspective, it is a natural requirement
that the obtained optimal control algorithm parameters are robust against the
variations of motor parameters. This is a crucial issue for the batch production of
novel drive systems [6971].
To nd effective ways to deal with this problem, several robust design optimization methods have been investigated, such as Taguchi method [7277] and
Six-Sigma robust optimization method [6971, 78]. These two methods have been
found useful to optimize motor performances (including torque ripples, cost, and
output power) and quality against the manufacturing tolerances.
Fig. 1.13 Proposed design framework of drive systems for mass production
18
Introduction
1.4
19
1.5
20
Introduction
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