A Manufacture Driven Topology Optimization of Laser Cut Synchronous Reluctance Machine

Synchronous reluctance machines are receiving attention, as they combine high efficiency with low material cost. The design of high-performance synchronous reluctance rotors is complex, and tends to benefits from using topology optimization which is often computationally intensive when FEA based. Significant discrepancy can occur between measured prototype performance and such FEA based simulation, attributed in part to the manufacturing processes. These factors can be large when stator and rotor core packs are fabricated by laser cutting. This paper presents a level set optimization approach, with degradation modelling, to adapt designs for manufacture during the optimization process. The results show topological changes and a reduction in torque deficit, when manufacturing degradation is included. Further work will look at the implications of varying degradation levels, to selectively increase degradation in critical regions of a rotor to enhance performance.