Multi-Objective Taguchi-FEM Optimization and Prototype-Based Verification of a Permanent Magnet Mechanical Clutch

This study evaluates a preliminary multi-objective optimization framework for a permanent magnet mechanical clutch designed for automated curtain actuators. To analyze the highly non-linear trade-off between disengagement capability (Y-direction magnetic resistance) and positional stability (Z-direction magnetic attraction force), a numerical approach combining three-dimensional (3D) magnetostatic finite element method (FEM) simulations, Taguchi L9 orthogonal arrays, and regression modeling was implemented. Three magnetic bead diameters were introduced as noise factors to investigate the sensitivity of the magnetic forces within a controlled simulation environment. A multiplicative composite objective function was employed to assess the competing performance criteria without masking single-factor failures. Statistical analysis indicates that within the investigated design space, the axial distance (Factor D) is the primary geometric parameter influencing the force distributions, followed by the outer diameter (Factor B) and inner diameter (Factor A). The identified parameter configuration (A = 8 mm, B = 10.5 mm, C = 0.5 mm, D = 1.5 mm) demonstrated an improved composite objective value and narrower standard deviations under the designated simulation boundaries compared to the initial discrete trials. These exploratory findings suggest that the proposed workflow was validated using a physical prototype based on one of the Taguchi configurations.