MULTI-OBJECTIVE TOPOLOGICAL OPTIMIZATION OF A PERMANENT-MAGNET SYNCHRONOUS MOTOR FOR AGRICULTURAL MACHINERY
DOI 10.12737/2073-0462-2025-20-4-100-106 УДК 621.313.1
Keywords:
topology optimization, electric machine, synchronous motor, modeling, genetic algorithmAbstract
The relevance of this study is due to necessity to improve the energy efficiency and reliability of electric drives used in agricultural machinery operating under extreme conditions: high dustiness, unstable loads, seasonality of operation and limited cooling. To design electric motors resistant to these factors, the author has modernized a topology optimization method previously tested on low-power electric vehicles. This article examines the application of topology optimization for permanent-magnet synchronous motors in agricultural machinery, taking into account the specific operating conditions, including high dustiness, unstable loads and limited cooling capabilities. A multi-criteria objective function is proposed that integrates the key operating parameters of permanent magnet synchronous motors: active material mass (weight factor of 0.25), electromagnetic losses (0.35), maximum temperature (0.25) and magnetic induction pulsation (0.15). The initial motor configuration (50 kg mass, 1200 W losses, 110°C temperature, 20 mT pulsation) is optimized using a genetic algorithm. Based on an estimated calculation over 10 iterations, the objective function is reduced from 0.944 to 0.788 while simultaneously improving all parameters: mass is reduced by 11%, losses by 27.7%, temperature by 13.6%, and pulsation by 26%. A graph of the objective function change and tables of parameters by iterations are presented, and the magnetic induction field is calculated. Clearly, the solution’s efficiency will decrease with practical implementation, but even preliminary results confirm that topology optimization allows for adapting motor design to the specifics of agricultural machinery, resulting in reduced weight, increased energy efficiency, and increased service life under multifactorial conditions. The developed approach eliminates traditional tradeoffs between weight, losses, and thermal performance, offering a comprehensive solution for the stable operation of electric drives in the agricultural sector.
References
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1. Allaire G, Gfrerer MH. Autofreefem: automatic code generation with FreeFEM and LaTex output for shape and topology optimization of non-linear multi-physics problems. Structural and multidisciplinary optimization. 2024; Vol.67. No.12. 213 p. doi: 10.48550/arXiv.2407.11713.
2. Babcock T, McKeever B, Hicken JE. Electrothermal coupling methodologies and their influence on the optimization of aircraft electric motors. AIAA Journal. 2024; Vol.62. No.7. 2659-2677 p. doi: 10.2514/1.J063627.
3. Baeck L, Blauth S, Leithauser C. Topology optimization for uniform flow distribution in electrolysis cells. PAMM. 2023; Vol.23. No.3. e202300163 p. doi: 10.1002/pamm.202300163.
4. Petrov T, Safin A. Modification genetic algorithm for topological optimization the rotor of synchronous motors. Lecture Notes in Civil Engineering. Proceedings of ICEPP. 2021; Vol.190. 151-156 p. doi: 10.1007/978-3-030-86047-9_16.
5. Safin A, Petrov T. Topological optimization of the rotors of permanent magnet synchronous motors. E3S Web Conf. 2020; Vol.220. 01040 p. doi: 10.1051/e3sconf/202022001040.
6. Cesarano A, Dapogny C, Gangl P. Space-time shape optimization of rotating electric machines. Mathematical models and methods in applied sciences. 2024; Vol.34. No.14. 2647-2708 p. doi: 10.48550/arXiv.2402.07017.
7. Gangl P. A multi-material topology optimization algorithm based on the topological derivative. Computer Methods in Applied Mechanics and Engineering. 2020; Vol.366. 113090 p. doi: 10.1016/j.cma.2020.113090.
8. Gangl P, Sturm K. Automated computation of topological derivatives with application to nonlinear elasticity and reaction-diffusion problems. Computer Methods in Applied Mechanics and Engineering. 2022; Vol.398. 115288 p. doi: 10.1016/j.cma.2022.115288.
9. Neofytou A, Rios T, Bujny M. Automatic differentiation-based level-set topology optimization for noise minimization in 3D domains considering acoustic-structure interaction. Structural and Multidisciplinary Optimization. 2025; Vol.68. No.3. 67 p. doi: 10.1007/s00158-025-03995-z.
10. Kim HJ, Baek SW. Optimal shape design to improve torque characteristics of interior permanent magnet synchronous motor for small electric vehicles. Microsystem Technologies. 2024; Vol.31. 1203-1217 p. doi: 10.1007/s00542-024-05699-8.
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