Multiphysics coupling analysis and structure optimization of flux switching permanent magnet linear motors

Area of Science:

• Electromagnetics and Applied Physics
• Mechanical Engineering and Materials Science
• Thermal Sciences and Heat Transfer

Background:

• High power density flux-switching permanent magnet linear motors (FSPMLMs) face challenges due to coupled thermal, electrical, and vibration phenomena.
• Optimizing these motors for a high power-to-weight ratio requires understanding complex multi-physics interactions.

Purpose of the Study:

• To develop a comprehensive framework for analyzing the coupled thermal-electrical-vibration behavior of FSPMLMs.
• To implement lightweight structure optimization techniques for enhancing the power-to-weight ratio of these motors.

Main Methods:

• A multi-physics finite element model integrating electromagnetic, thermal, and structural fields was established.
• Nonlinear electromagnetic-thermal and electromagnetic-vibration coupling analyses were performed.
• Topology optimization, specifically the bidirectional evolutionary structural optimization (BESO) approach, was employed for mass reduction.

Main Results:

• Nonlinear temperature rise patterns with hotspots in winding regions were identified.
• Critical correlations between thrust fluctuations and structural responses were established.
• The BESO approach achieved a 22.4% weight reduction while preserving performance characteristics.

Conclusions:

• The developed framework effectively analyzes multi-physics coupling in FSPMLMs.
• Lightweight structure optimization significantly impacts motor performance and is critical for high power-to-weight ratio applications.
• The methodology offers valuable insights for designing advanced electromagnetic actuators.