MSc on topology optimization of a Grundfos motor

Key points:
• We study a Grundfos motor/pump that uses rare-earth magnets.
• We wish to increase its sustainability by reducing the overall
material use without decreasing the performance of the motor.
• This will be done using topology optimization on a motor model to
study if the shape of the magnet, coils and steel can be optimized.
• Work together with the Grundfos motor team and DTU experts.

Challenge: A Grundfos motor, like all electromotors, uses permanent

magnets. It is critically important that these magnets provide the ideal
magnetic field, i.e. the field that results in the most efficient motor possible.

However, as the permanent magnets are made of rare-earth elements it is

also crucially important to limit the amount used in a motor as much as
possible, as the rare-earth materials are both rare, costly to mine, and subjective to geo-political supply
restrictions. Thus, it is highly sustainable to use the least amount of magnet material possible.

Similar arguments apply for the copper windings in the motor, which should also use the least amount of material
possible, without sacrificing performance, as copper is becoming an increasingly expensive material.

The requirement that optimizes motor performance, but use as little material, both magnet, copper and other
materials, as possible means that we must think of new ways to design the motor and optimize this.

Idea: In this project we want to explore a novel numerical

technique that can be used to design ideal geometries,
namely topology optimization. This is a technique that
optimizes a material layout within a given design space and
it would be ideal to attempt to determine a new design for
a Grundfos motor that fulfils the above requirements.

Your task: You will get to make a numerical model of a

Grundfos motor and apply topology optimization on this.
You will do this working together with the Grundfos motor team, as well as DTU experts.

Contact: Please contact Professor Rasmus Bjørk (rabj@dtu.dk) or contact Motor Specialist Frederik Valeur
(fvaleur@grundfos.com) if you are interested in hearing more about the project.