Multi-Material Topology Optimization with Continuous Magnetization Direction for Permanent Magnet Synchronous Reluctance Motors
Abstract
Permanent magnet-assisted synchronous reluctance motors (PMSynRM) have a significantly higher average torque than synchronous reluctance motors. Thus, determining an optimal design results in a multi-material topology optimization problem, where one seeks to distribute ferromagnetic material, air and permanent magnets within the rotor in an optimal manner. This study proposed a novel density-based distribution scheme, which allows for continuous magnetization direction instead of a finite set of angles. Thus, an interpolation scheme is established between properties pertaining to magnets and non-linear materials. This allows for new designs to emerge without introducing complex geometric parameterization or relying on the user's biases and intuitions. Toward reducing computation time, Nitsche-type mortaring is applied, allowing for free rotation of the rotor mesh relative to the stator mesh. The average torque is approximated using only four-point static positions. This study investigates several interpolation schemes and presents a new one inspired by the topological derivative. We propose to filter the final design for the magnetization angle using K-mean clustering accounting for technical feasibility constraints of magnets. Finally, the design of the electrical motor is proposed to maximize torque value.
Cite
@article{arxiv.2107.04825,
title = {Multi-Material Topology Optimization with Continuous Magnetization Direction for Permanent Magnet Synchronous Reluctance Motors},
author = {Thomas Gauthey and Peter Gangl and Maya Hage Hassan},
journal= {arXiv preprint arXiv:2107.04825},
year = {2026}
}