Structural Optimization and SVPWM Control Strategy of Rotary Motors for Plasma Spraying Applications

This study systematically investigates the structural optimization and control strategies of a plasma power supply-based rotating electrical machine. Firstly, stress simulation analysis was conducted on both conventional and optimized motor structures using ANSYS 2025 R1 software. The results demonstrate the maximum stress at the motor bearings decreased from 1.295 MPa to 0.865 MPa after optimization, representing a 33.2% reduction. Secondly, dynamic balance simulation performed with Adams 2024 software revealed that the centroid offset range of the optimized motor was reduced from ±0.05 mm to ±0.0175 mm, achieving a 65% improvement. Furthermore, a motor driver board supporting SVPWM and FOC algorithm was designed and implemented, featuring wide voltage input, multiple output channels, and comprehensive protection functions. Experimental verification confirmed that the developed control system could generate ideal three-phase saddle wave and sinusoidal current waveforms, ensuring smooth motor operation. The system demonstrated excellent dyne pen test results on plasma-sprayed acrylic plates, effectively validating the feasibility of both structural optimization and control strategies. The research outcomes provide theoretical foundations and technical support for high-performance motor design in demanding applications such as plasma spraying.