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This paper presents the use of genetic algorithms (GAs) and the Taguchi method in optimizing an surface-mounted permanent magnet
(SPM) motor for use as a fan motor in air-conditioners. GAs were used to optimize the efficiency of the motor, and the Taguchi optimiza-
tion method was used and the finite-element method (FEM) analysis was conducted to compute the performance of the motor design
generated by the Taguchi design of experiments.
Index Terms—Cogging torque, efficiency, finite-element (FE) analysis, genetic algorithms (GAs), surface-mounted permanent magnet
(SPM) motor, Taguchi optimization method.
I. INTRODUCTION
A. Objective Function
The objective function is the motor efficiency and is defined
as
(1)
Considering the demagnetization curve of ferrite magnet as a
The motor output power is already known. The losses straight line in second quadrant with the relative recoil perme-
consist of copper losses in the windings, core ability , the air gap flux density can be obtained by
losses , and stray losses which can be represented
as a function of design parameters as (6)
Keeping the flux density through the tooth and stator back
(2) iron below , gives
where is the phase current (A), is the winding resistance,
(7)
is the stator core volume m , is the mass density of the
stator core kg/m , is the loss density of the core
at peak flux density , and is electrical frequency, is Another constraints are given as follows:
the rated torque (Nm), and is the rated speed (rad/s).
When operated at rated speed and output power, the copper (8)
losses, and stray losses of the motor may be assumed constant.
The resistance of the windings and the stator core volume can where and are the width and height of the slot.
be calculated as Finally, according to the geometry of the motor, the bounds
of the design variables can be expressed as
(3)
(9)
(4)
C. Results
where is the number turns in a slot, is resistance of the wire
(ohms/km), is the axial stack length of the motor. In this study, results are obtained with populations ,
crossover , mutation . The final results
B. Design Variables and Their Limits are reported in Table I. The efficiency and peak to peak values
of cogging torque of the initial and the GAs optimal design are
In the present study, five geometrical variables are defined as 76.21% and 6.79 mNm, 79.25% and 3.689 mNm, respectively.
design variables. That is, , , ,
, , where is the magnet length, is the
tooth width, is the back iron width, and , are the high IV. TAGUCHI’S METHODOLOGY
of the shoe as shown in Fig. 2. The remaining design parameters In Taguchi’s parameter design method, an orthogonal array
can be expressed in terms of above variables or assigned fixed that depends on the number of factors and levels included is
values. used to study the parameter space [9], [10]. The performance
The permeance coefficient defining the operating point of the motor in the matrix experiments are computed using the
is given by FEA software [12].
TABLE II TABLE VI
LEVEL OF DESIGN VARIABLE AVERAGE PEAK-TO-PEAK VALUE OF COGGING
TORQUE FOR ALL LEVELS OF ALL FACTORS
TABLE III
VALUES OF THREE SETTINGS OF THREE DESIGN PARAMETERS
TABLE IV
MOTOR PERFORMANCE
TABLE VII
EFFICIENCY ALL LEVELS OF ALL FACTORS
TABLE V
ANALYSIS OF MEANS
TABLE VIII
EFFECTS OF VARIOUS FACTORS ON MOTOR PERFORMANCE INDEXES
VII. CONCLUSION
This paper applied the Taguchi methods to the design op-
timization for cogging torque minimization and efficiency
maximization of an SPM motor. It was shown that the tech-
Fig. 5. Optimized cross section of the SPM motor. nique presented in this paper is effective for obtaining the
TABLE IX design parameters having low levels of cogging torque and
COMPARISON RESULTS high efficiency. The technique would link the existing FEM
packages to complete an iterative design loop.
ACKNOWLEDGMENT
This work was supported by the National Science Council of
Taiwan under Grant NSC 96-2221-E-035-105.
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Manuscript received March 01, 2008. Current version published December
the Taguchi’s design are 6.7846 and 0.943 mNm, 76.21% and 17, 2008. Corresponding author: C.-C. Hwang (e-mail: cchwang@fcu.edu.tw).
78.45%, respectively. It is seen that reduction of cogging torque