3D Topology and Parametric Optimization of a Axial-Radial Flux PMSM with SMC Stator Core for Park Lock Actuators

The electric motor industry is constantly seeking innovative, cost-effective materials. Lamination steel designs usually begin with a 2D layout, but manufacturing complex 3D shapes is not feasible with lamination steels. The conventional approach of fixing the motor topology based on design experiences inherently establishes boundaries for optimization. Topology optimization can generate innovative 3D design shapes that can be manufactured using a soft magnetic composite stator core, utilizing either compaction or additive manufacturing techniques. This paper focuses on 3D topology optimization of an axial-radial SMC stator motor for a park lock actuator application. Extensive optimizations are conducted to enhance electromagnetic performance, including average torque and torque ripple. Finally, the results of 3D parametric optimization are presented and compared with topology optimization.