Manufacturability Oriented Topology Optimization of Interior Permanent Magnet Synchronous Motor

A large number of studies in Topology Optimization (TO) have aimed to enhance Interior Permanent Magnet Synchronous Motors (IPMSM) design. However, concerns persist regarding the manufacturability of the optimized designs, especially for simultaneously optimizing the geometry of permanent magnets (PMs) and back irons of the IPMSM. To improve the manufacturability of the optimized results of TO for the IPMSMs, this research proposes a manufacturing-focused TO approach for IPMSMs. Explicitly modelled basic components are initially developed and subsequently evolved through projective transformation and Boolean operations to generate novel topologies. Geometrical constraints are constructed and formulated to ensure the integrity of the iron in the optimized results. The numerical outcomes affirm the effectiveness of the proposed approach in substantially enhancing the performance parameter while preserving the manufacturability of the optimized designs.