Topology Optimization of Carbon-Taped Internal Permanent Magnet Machine with Non-Linear Mechanics Consideration

This work presents a topology optimization (TO) method applied to internal permanent magnet (IPM) machines, focusing on both magnetic and mechanical design requirements. In particular, the level-set method, combined with a gradient-based optimization approach, is employed to ensure the simultaneous improvement of electromagnetic performance and mechanical strength. Non-linear mechanical effects - such as magnet-iron contacts and the pre-charge stress introduced by carbon tape and the rotor shaft - are considered to ensure manufacturability and rotor structural integrity. First, a purely electromagnetic optimization is performed, illustrating that ignoring mechanical constraints can lead to impractical designs. Subsequently, a magneto-mechanical approach is introduced. The results show that accounting for realistic mechanical phenomena yields a feasible design that satisfies electromagnetic performance metrics such as torque and torque ripple, while preserving mechanical robustness.