System-Level Design Optimization Method for Electrical Drive Systems—Robust Approach

A system-level design optimization method under the framework of a deterministic approach was presented for electrical drive systems in our previous work, in which not only motors but also the integrated control schemes were designed and optimized to achieve good steady and dynamic performances. However, there are many unavoidable uncertainties (noise factors) in the industrial manufacturing process, such as material characteristics and manufacturing precision. These will result in big fluctuations for the product's reliability and quality in mass production, which are not investigated in the deterministic approach. Therefore, a robust approach based on the technique of design for six sigma is presented for the system-level design optimization of drive systems to improve the reliability and quality of products in batch production in this work. Meanwhile, two system-level optimization frameworks are presented for the proposed method, namely, single-level (only at the system level) and multilevel frameworks. Finally, a drive system is investigated as an example, and detailed results are presented and discussed. It can be found that the reliability and quality levels of the investigated drive system have been greatly increased by using the proposed robust approach.