Integrated optimization of 3D structural topology and 2D Halbach parameters for maglev planar motor

With the increasing demand of mechanical stiffness performance and electromagnetic performance of maglev planar motor, especially the moving-magnet motor with Halbach array, an integrated optimization with 3D structural optimization and magnet parameter optimization is proposed and executed in this paper. The macroscopic electromagnetic performances consisting of thrust-mass ratio and power dissipation are taken as the optimization objective, which improves the performance more directly and comprehensively than traditional optimization methods. A streamlined dual-loop optimization framework is constructed and proved to be able to reduce the computational consumption by tens of times compared to the initial conventional framework, authentically guaranteeing a smooth integrated optimization. At the outer loop of the optimization framework, this paper proposes an oriented strategy for the individuals of Genetic Algorithm (GA) to quickly meet the strict constraints. The integrated optimization method solves the parameter coupling problem between electromagnet and stiffness. Compared to existing optimized structure, the resulting structure improves the thrust-mass ratio by 7.7%, power dissipation by 12.8% and natural frequency by 16.6%, respectively. Mechatronic experimental results in maglev planar motor systems show that the proposed integrated optimization can significantly improve the control bandwidth and reduce the current consumption, laying the foundation for better performance in practical applications.