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In the context of the optimization of rotating electric machines, many different objective functions are of interest and considering this during the optimization is of crucial importance. While evolutionary algorithms can provide a Pareto front straightforwardly and are widely used in this context, derivative-based optimization algorithms can be computationally more efficient. In this case, a Pareto front can be obtained by performing several optimization runs with different weights. In this work, we focus on a free-form shape optimization approach allowing for arbitrary motor geometries. In particular, we propose a way to efficiently obtain Pareto-optimal points by moving along to the Pareto front exploiting a homotopy method based on second order shape derivatives., Comment: 9 pages, 3 figures. SCEE2024 conference proceeding paper

This article is devoted to the shape optimization of the internal structure of an electric motor, and more precisely of the arrangement of air and ferromagnetic material inside the rotor part with the aim to increase the torque of the machine. The governing physical problem is the time-dependent, non linear magneto-quasi-static version of Maxwell's equations. This multiphase problem can be reformulated on a 2d section of the real cylindrical 3d configuration; however, due to the rotation of the machine, the geometry of the various material phases at play (the ferromagnetic material, the permanent magnets, air, etc.) undergoes a prescribed motion over the considered time period. This original setting raises a number of issues. From the theoretical viewpoint, we prove the well-posedness of this unusual non linear evolution problem featuring a moving geometry. We then calculate the shape derivative of a performance criterion depending on the shape of the ferromagnetic phase via the corresponding magneto-quasi-static potential. Our numerical framework to address this problem is based on a shape gradient algorithm. The non linear time periodic evolution problems for the magneto-quasi-static potential is solved in the time domain, with a Newton-Raphson method. The discretization features a space-time finite element method, applied on a precise, meshed representation of the space-time region of interest, which encloses a body-fitted representation of the various material phases of the motor at all the considered stages of the time period. After appraising the efficiency of our numerical framework on an academic problem, we present a quite realistic example of optimal design of the ferromagnetic phase of the rotor of an electric machine.

This paper deals with the design optimization of a synchronous reluctance machine to be used in an X-ray tube, where the goal is to maximize the torque, by means of gradient-based free-form shape optimization. The presented approach is based on the mathematical concept of shape derivatives and allows to obtain new motor designs without the need to introduce a geometric parametrization. We validate our results by comparing them to a parametric geometry optimization in JMAG by means of a stochastic optimization algorithm. While the obtained designs are of similar shape, the computational time used by the gradient-based algorithm is in the order of minutes, compared to several hours taken by the stochastic optimization algorithm. Finally, we show an extension of the free-form shape optimization algorithm to the case of multiple objective functions and illustrate a way to obtain an approximate Pareto front., Comment: 6 pages, 7 figures, proceedings to IGTE Symposium Graz 2020