Robust Tolerance Design Optimization of a PM Claw Pole Motor With Soft Magnetic Composite Cores

In the past decades, various methods have been investigated for assessing performance variation and robust optimization for electromagnetic device design under uncertainties and/or tolerances. However, in actual production, the manufacturing tolerances are variable to a certain extent, which can be optimized for integrating the performance, manufacturing cost, and production quality. This paper proposes a tolerance design optimization approach by optimizing the design parameters and tolerances simultaneously based on design for six sigma technique. A permanent magnet claw pole motor with soft magnetic composite cores is optimized by using the proposed approach. For this high-dimensional optimization problem involving electromagnetic and thermal performance, Kriging model and 3-D thermal network model are employed under the multilevel framework for increasing the optimization efficiency. Finally, through the analysis, the proposed robust tolerance optimization method shows good performance with improved motor performance as well as the diversity controlling without cost increasing.