Nick J. Baker

In this paper, a sequential Taguchi method for design optimization of an induction motor (IM) for an electric vehicle (EV) is presented. First, a series of empirical and mathematical relationships is systematically applied to reduce the number of possible stator slot rotor bar (SSRB) combinations. Then, the admissible optimal combinations are investigated and compared using finite element (FE) simulation over the NEDC driving cycle, and the three best combinations are selected for further analysis. Each topology is optimized over the driving cycle using the k-means clustering method to calculate the representative working points over the NEDC, US06, WLTP Class 3, and EUDC driving cycles. Then, using the Design of Experiment (DOE)-based Taguchi method, a multi-objective optimization is carried out. Finally, the performance of the optimized machines in terms of robustness against manufacturing tolerances, magnetic flux density distribution, mechanical stress analysis, nominal envelope curve and efficiency map is carried out to select the best stator slot rotor bar combination. It is also found that the K-means clustering method is not completely robust for the design of electric machines for electric vehicle traction motors. The method focuses on regions with high-density working points, and it is possible to miss the compliant with the required envelope curve.

In this paper, two H-type flux switching permanent magnet linear generators with outer-translator and inner-translator configurations are discussed and compared to a more conventional flux switching topology. The stators consist of H-Type modules housing circumferential coils and are surrounded by two annular permanent magnets. In conventional flux switching machines, the windings are orientated perpendicular to the direction of motion and the conductors twist around the magnets. In H-type topologies, the orientation of the windings is in the same plain as the magnets and parallel to the direction of motion, resulting in an increase in flux linkage. The proposed topologies are designed for a low operating speed and a large magnetic gap, as found in wave energy converters. All topologies are optimized using the Taguchi optimization approach with the goals of reducing force ripple and increasing the average thrust force and efficiency. The 2D finite element method (FEM) is used in the optimization stage to calculate the optimized parameters of the presented generators, after which the optimized structures are simulated using 3D FEM, and the results are extracted. The results of the optimization show that the H-type topologies deliver a 20% higher shear stress whilst offering an easier to assemble structure.