Topology Optimization of Synchronous Reluctance Motors Considering the Optimal Current Reference in the Field-Weakening and Maximum-Torque-Per-Voltage Regions

The torque performance of the synchronous reluctance motors (SynRMs) is primarily determined by the geometric design and current control. The motor structure needs to be designed to yield the maximum output torque under the given current and voltage limitations. The current reference supplied to the stator coils also needs to be determined to maximize the output torque while suppressing the back electromotive force (EMF) to protect a power supply system. However, in the field of design optimization, it has been challenging to simultaneously consider the geometric design and current control due to their complicated relationships. To solve the aforementioned issue, this study proposes a new topology optimization that can cover the maximum-torque-per-ampere (MTPA), field weakening (FW), and maximum-torque-per-voltage (MTPV) controls under both the current and voltage limitations, thereby maximizing the output torque in an entire rotational speed range. To effectively investigate the coupling effects between the geometric design and current reference, this study proposes the design parameterization for the FW and MTPV operation by performing the electromagnetic finite element (FE) analysis and then expresses the optimal current reference in terms of design variables. At every iteration, the structural FE analysis is also performed under the design-dependent loads to obtain a structurally meaningful design. By doing so, both the optimal design and the corresponding optimal current reference can be simultaneously determined. The optimized SynRM is manufactured and experimentally validated to demonstrate the effectiveness of the proposed optimization framework.