Journal of Mechanical Science and Technology 34 (3) 2020
1007/s12206-020-0223-3
Journal of Mechanical Science and Technology 34 (3) 2020
Original Article
DOI 10.1007/s12206-020-0223-3
Keywords:
· Interior permanent magnet synchro-
nous motor
· Manufacturing uncertainty
· Torque ripple
· Reliability
· Metamodel
· Reliability-based robust design optimi-
zation
Correspondence to:
Seunghyeon Cho
jobu88@hanyang.ac.kr
Citation:
Jang, G. U., Kim, C.-W., Bae, D., Cho, Y.,
Lee, J.-J., Cho, S. (2020). Reliability-
based robust design optimization for
torque ripple reduction considering manu-
facturing uncertainty of interior permanent
magnet synchronous motor. Journal of
Mechanical Science and Technology 34
(3) (2020) 1249~1256.
http://doi.org/10.1007/s12206-020-0223-3
Received October 9th, 2019
Revised November 5th, 2019
Accepted November 22nd, 2019
† Recommended by Editor
Seungjae Min
© The Korean Society of Mechanical
Engineers and Springer-Verlag GmbH
Germany, part of Springer Nature 2020
DOI 10.
Reliability-based robust design
optimization for torque ripple reduction
considering manufacturing uncertainty of
interior permanent magnet synchronous
motor
Gyeong Uk Jang1, Chang-Wan Kim2, Daesung Bae3, Younghoon Cho4, Jeong-Jong Lee5
and Seunghyeon Cho3
1
Graduate School of Mechanical Design of Production Engineering, Konkuk University, Seoul 05029,
Korea, 2School of Mechanical Engineering, Konkuk University, Seoul 05029, Korea, 3School of Mechani-
cal Engineering, Hanyang University, Ansan 15588, Korea, 4Department of Electrical Engineering,
Konkuk University, Seoul 05029, Korea, 5Intelligent Mechatronics Research Center, Korea Electronics
Technology Institute, Puchon 14502, Korea
Abstract This study performed reliability-based robust design optimization (RBRDO) of stator
and rotor shape of the IPM type electric motor to reduce the torque ripple considering uncertainties.
A metamodel based on the design of experiments results, which was calculated by using 2-D
electromagnetic finite element analysis, was used to calculate manufacturing uncertainties and
material property distribution. As a result, the mean torque ripple of the optimum electric motor
design was reduced by 56.4 % and the robustness was increased by 61.8 % compared with the
initial design. The RBRDO design was compared with the designs of deterministic design
optimization and reliability-based design optimization, and it was shown that, by using the RBRDO
method, the optimum IPMSM can be designed to satisfying not only the minimum torque ripple but
also the robustness and the reliability of output torque and torque ripple.
1. Introduction
Generally, an interior permanent magnet synchronous motor (IPMSM) was mainly used as a
traction motor for electric vehicles, because of enabling higher efficiency, higher output torque
and miniaturization due to the reluctance torque [1]. On the other hand, the reluctance torque
was source of increasing torque ripple, which was source of electromagnetic vibration of the
electric motor.
For this reason, many studies on reducing the torque ripple of the IPMSM have been con-
ducted. In the initial studies, the design methods of the stator core shape that easy to change
the design parameters was studied to torque ripple reduction. To reduce the torque ripple of the
PMSM, Liu et al. studied the effects of applying the curvature of the slot end and the rotor skew
[2]. Do et al. applied a slit to rotor for reducing the torque ripple of the IPMSM wherein magnetic
flux concentration occurs locally [3].
By the development of the various optimum design methods, researchers have utilized opti-
mization methods with the rotor and stator shape dimension of the electric motor as design
variables. Kwack et al. performed topology optimization for the design region of the slot end to
reduce the torque ripple of the IPMSM and changed the volume fraction of the design region [4].
To reduce the cogging torque for a single-phase BLDC motor, Park et al. applied a notch to a
stator and performed size optimization [5]. Cho et al. applied the Taguchi method to optimize
rotor and stator shapes in order to reduce the cogging torque of the IPMSM [6]. Lukaniszyn et
al. applied a genetic algorithm to optimize shape in order to reduce the cogging torque of per-
manent magnet synchronous motors [7].
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 Journal of Mechanical Science and Technology 34 (3) 2020 DOI 10.1007/s12206-020-0223-3

Recently, there are studies that take into account the uncer- Table 1. IPMSM specification.
tainties which arise in manufacturing process unlike conven-
Specification Value
tional deterministic design optimization (DDO). Since the
above uncertainties cause the probabilistic distribution of the Max voltage 500 V
output torque or torque ripple of the electric motor, manufac- Peak torque 400 N·m
tured electric motor that do not satisfy the required torque
Peak power rating 50 kW at 1200 rpm
specifications may occur in the same manufacturing process.
Accordingly, several optimization studies [8-11] on reliability- Stator slots 48 slots
based design optimization were conducted to address the Pole 8 poles
unsatisfactory torque performances of the electric motor due
to manufacturing uncertainty. Jang et al. performed reliabil-
ity-based robust design optimization (RBRDO) to optimize
back-EMF while accounting for the reliability of cogging
torque for electric power steering motors [8]. Lee et al. per-
formed robust design to minimize back-EMF for the IPMSM
[9]. Meanwhile, Wu et al. used the DMADV method, a six-
sigma technique, to secure output torque reliability for
IPMSM [10]. To apply reliability-based design optimization
(RBDO) within the field of electromagnetism, Kim et al. per- (a) (b)
formed various design optimizations while considering the
reliability and robustness of the design variables that deter-
mine the shape and location of the permanent magnet for
the cogging torque optimization of BLDC motors. Subse-
quently, the researchers conducted a comparative analysis
of the optimization results [11].
However, in case of permanent magnet type electric motor,
the magnetic properties such as retentivity and permeability
(c) (d)
of the permanent magnet also affects the torque perform-
ance. Therefore, the reliability of the electric motor torque Fig. 1. Geometry of IPMSM: (a) and (b) IPMSM model; (c) FEA full model;
ripple and output torque may be decreased by not only the (d) FEA 1/8 symmetry model.
manufacturing uncertainties, but also distribution of the per-
manent magnet material properties. In addition, it requires 2. Electromagnetic finite element analysis
many iterations when the reliability-based design optimiza- of IPMSM
tion was conducted to calculate the probabilistic distribution 2.1 IPMSM specification
and optimum solution [12]. Hence, it is necessary to adopt a
method to save computing time to perform the reliability- This study used an 8-poles 48-slots IPMSM, which is used
based design optimization. as the traction motor for electric vehicles. The maximum volt-
In this study, the RBRDO was performed to reduce the age of the motor is 500 V, maximum torque output is 400 N·m,
torque ripple and increase the reliability of the output torque and maximum power is 50 kW; these values are listed in Table
for the IPMSM by considering not only the uncertainties of 1 in detail. Figs. 1(a) and (b) show the actual IPMSM motor [13].
the stator and rotor shape dimensions, but also the uncer- To perform the 2-D electromagnetic FEA, the cross-section
tainties of the permanent magnet material properties. At first, geometry of the IPMSM was created as shown in Fig. 1(c).
a 2-D electromagnetic finite element analysis (FEA) calcu- Then, the 1/8 symmetry as shown in Fig. 1(d) was used for 2-D
lates the output torque and torque ripple of the initial design electromagnetic FEA to reduce the computing time.
of IPMSM. Then, the reliability of the calculated output
torque and torque ripple was computed by using the meta- 2.2 Electromagnetic finite element analysis
model based on the design of experiment (DOE) data. Fi-
nally, the RBRDO was conducted to reduce not only the First, the electromagnetic finite element analysis (FEA) was
mean torque ripple but also the standard deviation of the performed by using the 1/8 axisymmetric model of the IPMSM.
torque ripple by using the design variables, which were As the analysis condition, a three-phase alternating current
composed both the mean value and distribution of the stator was applied for the motor to generate torque at a constant
and rotor shape dimensions and of the permanent magnet rotational speed. FEA results of the magnetic flux density of
material properties. Then, the advantages of RBRDO meth- axisymmetric IPMSM and output torque was shown in Fig. 2. In
ods for IPMSM optimum design to reduce the torque ripple Fig. 2(b), the output torque was periodically changed, which is
are discussed using the RBDO and DDO method. torque ripple. From the output torque results, it was found that

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 Journal of Mechanical Science and Technology 34 (3) 2020 DOI 10.1007/s12206-020-0223-3

Table 2. IPMSM design variables.

Classification Variable Description

x1 Width of magnet

x2 Length of magnet

x3 Angle of magnet
(a)
x4 Bridge

Design variable x5 Width of slot

x6 Depth of slot

x7 Tooth tip angle

x8 Tooth tip length

x9 Width of tooth

x10 Residual magnetic flux density

(b) Non-design variable
x11 Relative permeability
Fig. 2. Analysis result of Electromagnetic FEA: (a) Magnetic flux density of
IPMSM; (b) output torque of IPMSM.

the torque ripple was 109.46 N × m and the output torque was
389.79 N × m.

2.3 Metamodel generation using design of ex-

periment
For the reliability analysis, many sampling points are needed
to identify the relation between the distribution of each variable
(a) (b)
and response. For this reason, to efficiently identify the reliabil-
ity, metamodel generated from DOE was used to calculate the Fig. 3. Design variables of IPMSM: (a) Rotor design variables; (b) stator
response values at each sampling point. design variables.
In this study, we applied the Latin Hypercube sampling
method, a space-filling experimental design method suitable for In the metamodel generated in this study, the output torque
a large number of design variables and applicable to various response was calculated to be 0.99953 and the torque ripple
models [14]. Accordingly, we employed the Latin Hypercube response to be 0.99658, demonstrating that the relationship
sampling method to confirm the torque ripple and output torque between the design variables and the response values of the
at 1000 levels for 11 design variables. We then used the radial metamodel is very accurate.
basis function (RBF) model to generate the metamodel based
on the produced sampling points. The RBF model is an inter- 3. Reliability-based robust design optimi-
polation model that uses the radial function as its basis function zation of IPMSM
and is widely used in computational analysis for its perform-
3.1 Reliability analysis of initial IPMSM model
ance in expressing nonlinearity and ease of creating meta-
models [15]. In general, the rotor and stator of the motor produce a sin-
The accuracy of the generated metamodel can be derived gle sheet through the stamping process. Here, owing to
through R-square, as shown in Eq. (1), using the data of DOE. various environmental factors and production equipment
The closer the value to 1, the more accurate is the model. errors in the manufacturing process, distribution in the
physical properties of the permanent magnet and that
2
n
caused by manufacturing tolerance of the shape may occur.
R 2
=1-
å éë y - y ùû
i =1 i i
(1)
n 2 The distribution of these design factors results in uncertain
å [ y - y]
i =1 i response values, i.e., motor output torque. Further, it can
potentially not satisfy the desired output torque requirements
where yi , y is analysis result in one experiment point and of the motor designer.
average of all experiment points, respectively, and yi is ex- In optimal design, it is advantageous to adjust design vari-
pectation value by metamodel. ables which are easy to control. The rotor and stator shape

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 Journal of Mechanical Science and Technology 34 (3) 2020 DOI 10.1007/s12206-020-0223-3

Table 3. Reliability analysis of Initial IPMSM. where Φ ( X i ) is Gaussian distribution function, x is value
of variable, μ is mean, and σ is standard deviation.
Mean 389.74
Output torque [N∙m] After applying the above distribution to each design vari-
Standard deviation 7.460 able, we obtained the distribution of the motor torque re-
sponse through the Latin hypercube sampling method.
Mean 109.36
Torque ripple [N∙m] When extracting the values from the space of each random
Standard deviation 2.727 design variable X i , each range is divided into N regions
such that an equal distribution frequency in the probability
Failure 9.63 %
distribution function Φ ( X i ) considering uncertainty is at-
tained. The N non-overlapping points in each section are
then extracted.
In this study, we extracted 10000 level points using the
Latin Hypercube sampling method, applied the metamodel
generated above to derive the distribution of the response
values, and calculated the mean Ê and standard deviation
σ̂ using Eqs. (3) and (4), respectively. The response value
distribution for each output torque and torque ripple was
calculated as shown in Figs. 4(a) and (b), respectively; Table
3 summarizes the results. Here, the performance satisfying
the motor is defined to be within ±5 % of the maximum
torque of 400 N·m, and the failure of the output torque is
(a) derived.

E ( yi ) = Eˆ ( yi ) =
å i =1
yi
(3)
N
n 2
å é Eˆ ( yi ) - yi ù
ë û
σ 2
( y ) = V ( y ) = Vˆ ( y ) =
i i i
i =1
(4)
N

where Ê is mean, Vˆ is deviation, σ̂ is standard deviation,

yi is response value, and N is the number of sampling level.

(b) 3.2 Reliability-based robust design optimiza-

Fig. 4. Distribution of Initial IPMSM: (a) Output torque; (b) torque ripple.
dimensions are easily modified on the design stage. How-
ever, since the properties of the permanent magnet were
standardized production. Therefore, nine design variables
that determine the shape of the motor rotor and stator, as
shown in Fig. 3, are selected along with two physical prop-
erty of permanent magnet for determining the output torque
[16]. These are summarized in Table 2. A Gaussian distribu-
tion was then applied to a total of 11 factors as shown in Eq.
(2) to considering uncertainty. Using the shape tolerance
standard deviation of 0.05 mm, this study assumed a 2σ
reliability (95 % reliability). Further, referring to the datasheet
of a magnet manufacturer, it used a residual magnetic flux
density of 0.02T and specific relative permeability of 0.04,
thus defining 2σ reliability.
2
-( x - μ )
1 2σ 2
Φ ( xi ) = e (2)
2Õσ 2
tion considering manufacturing uncertain-
ties
Optimization has been conducted through conventional
methods using deterministic values without considering distri-
bution caused by the uncertainty of design variables. However,
when considering the distribution of each variable, the re-
sponse distribution may not satisfy the constraint or required
output torque of the motor. To this end, a RBDO method that
considers for the distribution of design variables during optimi-
zation is necessary [17]. Accordingly, the shape of the IPMSM
should be optimized through RBRDO.
Owing to the uncertainty that may occur during manufactur-
ing, this study performs RBRDO considering the distribution of
the design variables. This study employed system reliability
optimization (SRO) that considers the overall stability of the
system. This technique is suitable when there are various con-
straints [18].
In this study, the design variables for nine variables, which
determine the shape of the rotor and stator of the motor, opti-
mized by the optimum design formulation which is shown as
follows:

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Table 4. Design variables of RBRDO result. Table 5. Reliability analysis of Initial and RBRDO solution model.

Design variables Initial RBRDO Initial RBRDO

x1 5 5.15 Mean 389.74 400.54
Output torque [N∙m]
x2 54 48.62 Standard deviation 7.460 7.129
x3 140 136.01 Mean 109.36 47.68
Torque ripple [N∙m]
x4 1 1.10 Standard deviation 2.727 1.119
x5 2 2.05 Failure 9.63% 0.32 %
x6 30 30.4

x7 40 42.71

x8 1 1.01

x9 6.5 7.15

(a)

Fig. 5. Optimal point of RBRDO.

Find . xi (i = 1, L, 9)
min. μ f ( X i , Yi ) , σ f ( X i , Yi )
S .t. G j = Pr ( g j ( X , Y ) ³ 380 N × m ) ³ 0.99
G j = Pr ( g j ( X , Y ) £ 420 N × m ) ³ 0.99
Magnet area £ 270 mm 2
Ai µ N ( X i ,0.052 ) , i = 1,L,9
( )
Bi µ N Yi , σ pi 2 , i = 1, 2
where X represents the nine controllable variables that deter-
mine the shape of the motor (design variable), Y represents the
two uncontrollable for the permanent magnet properties of the
motor (non-design variable), f is a function of torque ripple, and
G, g are a function of output torque. Here, the function of
torque ripple is a multi-objective function of the mean distribu-
tion of the response μ f and the distribution standard devia-
tion σ f . To maintain the performance of the motor, the limiting
function was set to ± 5 % of the maximum torque of 400 N × m
(b)
Fig. 6. Comparison distribution Initial and RBRDO solution model: (a) Out-
put torque; (b) torque ripple.
- a lower bound of 380 N × m and an upper bound of 420 N × m.
The magnet area was set to not exceed the existing area to
consider the manufacturability.
Owing to the optimization, as shown in Fig. 5, the objective
function converges to 13 optimal points during the 332nd itera-
(5)
tion. Out of 13 optimal solutions, a solution calculated with the
minimum mean value and standard deviation of the torque
ripple was selected. Table 4 summarizes the optimization re-
sults of the design variables. To derive the reliability of the op-
timization model, after applying distribution on the design vari-
ables during optimization, the Latin hypercube sampling
method was used in the same manner as before to determine
the reliability of the RBRDO optimization model. The distribu-
tion of the RBRDO optimization model was calculated as
shown in Fig. 6, while Table 5 summarizes the obtained results
compared with those of the initial model.

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 Journal of Mechanical Science and Technology 34 (3) 2020 DOI 10.1007/s12206-020-0223-3

Table 6. Optimum design formulation of DDO, RBDO, and RBRDO method.

DDO RBDO RBRDO

Objective Minimize f Minimize m f ( X i , Yi ) Minimize m f ( X i , Yi ) , s f ( X i , Yi )

G ³ 380 N × m G j = Pr ( g j ( X , Y ) ³ 380 N × m ) ³ 0.99 G j = Pr ( g j ( X , Y ) ³ 380 N × m ) ³ 0.99

Constraint G £ 420 N × m G j = Pr ( g j ( X , Y ) £ 420 N × m ) ³ 0.99 G j = Pr ( g j ( X , Y ) £ 420 N × m ) ³ 0.99
Magnet area £ 270 mm 2 2
Magnet area £ 270 mm Magnet area £ 270 mm 2

Table 7. Reliability analysis of DDO, RBDO, and RBRDO solution model.

DDO RBDO RBRDO

Mean 380.0 398.94 400.54
Output torque [N∙m]
Standard deviation 7.195 7.195 7.129
Mean 44.99 47.26 47.68
Torque ripple [N∙m]
Standard deviation 1.052 1.145 1.119
Failure 51.8 % 0.67 % 0.32 %

(a)

Fig. 7. Reliability analysis and design optimization process: DDO, RBDO

and RBRDO method.

4. RBRDO results comparison with DDO

and RBDO methods
Based on the results of the RBRDO process, as shown in
Fig. 7, this study conducted various design optimizations to the
IPMSM motor using the metamodel generated through DOE to
the reliability of response in each design optimization methods.
We first studied the results of DDO, which demonstrates the
effect of considering design variable distribution. Second, we
studied the results of RBDO, which demonstrates the effect of
robust design. Table 6 summarizes the formulation of each
design optimization method.
For DDO, a gradient-based optimization technique sequen-
tial quadratic programming (SQP) was used for design optimi-
zation. Owing to the optimization, although DDO exhibits a
greater reduction in torque ripple than the result of RBRDO, the
output torque converges at the end of the formulated constraint.
However, applying the design variable distribution to the DDO
(b)
Fig. 8. Comparison distribution of DDO, RBDO, and RBRDO solution model:
(a) Output torque; (b) torque ripple.
results considerably increases the failure of the output torque,
which was defined as the constraint. This confirms the neces-
sity of considering the reliability of output torque performance
because of design variables distribution.
RBDO is an optimization method that does not consider ro-
bust design. Owing to optimization, the output torque con-
verged similarly to RBRDO due to the constraint; however,
considering the design variable distribution through the meta-
model, standard deviation of the response was more optimized

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 Journal of Mechanical Science and Technology 34 (3) 2020
than RBRDO because robust design was not considered.
Thus far, we have the results of DDO and RBDO with
RBRDO. Table 8 summarize the optimization results for each
case. Fig. 8 shows the reliability analysis of the response con-
sidering design variable distribution at the optimal point of each
design optimization method.
The optimum solution using RBRDO was compared with
that using DDO and RBDO. DDO conducts optimization with-
out considering distribution, thus producing the best result in
the terms of minimizing the objective function. However, DDO
solution, which does not consider manufacturing uncertainties,
has 51.8 % failure and it is not optimum solution. In RBDO,
which does not consider robust design, the standard devia-
tion is larger than that of RBRDO, resulting in a large distribu-
tion of the objective function. However, for RBRDO, which
considered together reliability and robust design, minimize
mean and standard deviation of response function. Therefore,
when the manufacturing uncertainty is considered, RBRDO
solution satisfies the required performances, and it is better
optimal solution than DDO and RBDO solution. For these
reasons, in electric motor design optimization, the reliability
and robustness of motor dimension must be considered to-
gether with optimization of the objective function.
5. Conclusions
In this study, the metamodel based reliability-based robust
design optimization of the IPMSM stator and rotor shape was
performed to reduce the torque ripple as well as increase the
reliability of the torque ripple.
Firstly, the RBF metamodel was generated by using the
Latin Hypercube sampling-based DOE results calculated by
2-D electromagnetic FEA. By using the generated metamodel,
the reliability analysis of the initial IPMSM was conducted to
calculate the mean and the standard deviations of the torque
ripple and output torque. Secondly, the RBRDO was con-
ducted to reduce the standard deviation and mean of the
torque ripple. As a result, the reliability of the torque ripple
was reduced by 61.9 % and the mean of torque ripple was
reduced by 56.4 % compared with the initial IPMSM. Also,
the reliability of the output torque was significantly high at
99.68 %.
Finally, the optimum solution of RBRDO was compared with
that of DDO and RBDO. In the DDO solution, even though the
torque ripple of the optimum solution was the smallest among
the three optimum methods, the reliability of the torque ripple
was 51.8 %. Also, in the RBDO solution, the standard devia-
tions of the optimum solution were larger than that of RBRDO.
On the other hand, in the RBRDO solution, optimum model has
the minimum torque ripple and guarantee of the torque ripple
reliability at the same time. From comparison among the opti-
mum solutions calculated by RBRDO, RBDO, and DDO, it was
found that using the RBRDO methods was the best optimum
method to reduce the torque ripple of the IPMSM considering
uncertainties.
DOI 10.1007/s12206-020-0223-3
Acknowledgments
This research was supported by Human Resources Program
in Energy Technology of the Korea Institute of Energy Tech-
nology Evaluation and Planning (KETEP), granted financial
resource from the Ministry of Trade, Industry & Energy, Repub-
lic of Korea (Grant No. 20194010201790), and the National
Research Foundation of Korea (NRF) grant funded by the Ko-
rea government (MSIT) (No. 2019R1A2C1090228).
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Gyeong Uk Jang was born in Seoul city,
Republic of Korea, in 1993. He received
the B.S. degree in mechanical engi-
neering from Konkuk University, Seoul,
Republic of Korea, in 2019. He is
currently working toward the M.S. degree
in mechanical design and production
engineering at Konkuk University, Seoul
city, Republic of Korea. His research interests include design
optimization, vibration and noise of motor.
1256
DOI 10.1007/s12206-020-0223-3
Chang-Wan Kim was born in Pohang
city, Republic of Korea, in 1969. He
received the B.S. degree in mechanical
engineering from Hanyang University,
Seoul, Republic of Korea, in 1987. He
received the M.S. degree in mechanical
engineering from Pohang University of
Science and Technology, Pohang, Re-
public of Korea, in 1993. He received the M.S. degree in com-
putational applied mathematics, and Ph.D. degree in aero-
space and engineering mechanics from University of Texas at
Austion, Texas, USA, in 1997 and 1999, respectively. He is
currently a Professor of Department of Mechanical Engineering,
Konkuk University, Seoul city, Korea. His research interests
include vibration and noise analysis, multi-body dynamics, finite
element analysis, and multi-physics analysis of system.
Daesung Bae received the B.S. degree
in mechanical engineering from Hanyang
University, Seoul, Republic of Korea, in
1982. He received the M.S. and Ph.D.
from the University of Iowa, Iowa, USA,
in 1983 and 1986, respectively. He had
worked as an Assistant Adjunct Pro-
fessor in University of Kansas, an Invi-
tation Professor in University of Penn State and a Senior Re-
searcher in BMY Combat System. Now, he is working as a Pro-
fessor in Hanyang University, Seoul, Republic of Korea. His
present research interests are in multibody dynamics, analysis of
finite element method, kinematic & kinetic simulation and nu-
merical analysis for design and simulation of mechanical system.
Seunghyeon Cho was born in Seoul
city, Republic of Korea, in 1988. He
received the B.S. and M.S. degrees in
mechanical design and production
engineering from Konkuk University,
Seoul, Republic of Korea, in 2014 and
2016, respectively. He is currently
working toward the Ph.D. degree in
mechanical design engineering at Hanyang University, Seoul
city, Republic of Korea. His research interests include vibration
and noise of motor system, multi-body dynamics of mechanical
system, and optimum design.