Design and Optimization of a Permanent Magnet Synchronous Motor for a Two-Dimensional Piston Electro-Hydraulic Pump

Abstract

A two-dimensional (2D) piston electro-hydraulic pump has been proposed further to enhance the power density of the electro-hydraulic pump. The 2D piston pump, characterized by high power density and a slender shape, is embedded within the stator of the motor in a co-rotor configuration where the piston and the motor’s rotor are in tandem. The intimate design of the hydraulic pump and the motor results in a coupling between the two, with intricate relationships and influences existing between the geometric parameters of the piston pump and the dimensions of the motor’s rotor. Based on the operational requirements and structure of the 2D piston pump, a permanent magnet synchronous motor (PMSM) designed for use with a 2D piston electro-hydraulic pump is developed. This study examines the impact of the motor’s stator iron core geometric parameters on both the electromagnetic and mechanical properties of a PMSM and completes the necessary performance validations. The optimization objectives of the motor are determined through an analysis of the influence of the key parameters of the rotor and stator on torque, torque ripple, and motor loss. A surrogate optimization model is constructed using a metamodel of optimal prognosis (MOP) to optimize the torque, torque ripple, and motor loss. Evolutionary genetic algorithms are utilized to achieve the multi-objective optimization design. A finite element simulation is used to compare the electromagnetic performance of the initial motor and optimal motor. Based on the optimal motor parameters, a 2.5 kW motor prototype is manufactured, and the experimental results validate the feasibility and effectiveness of the motor design and optimization.

Keywords

• two-dimensional piston electro-hydraulic pump
• permanent magnet synchronous motor
• metamodel of optimal prognosis
• multi-objective optimization
• evolutionary algorithm