Analysis and Optimization of Electromagnetic Vibration of Permanent Magnet Synchronous Motors for Unmanned Underwater Vehicles

Driven by the engineering requirement for high acoustic stealth of unmanned underwater vehicles (UUVs), this paper investigates the electromagnetic vibration of an 8-pole, 48-slot, surface-mounted permanent magnet synchronous motor (SPMSM) employed in the propulsion system through multi-physics coupling analysis and experimental testing. First, analytical calculations of electromagnetic force waves are performed based on the Maxwell stress tensor method and the magnetomotive force–permeance method to analyze the spatial orders, temporal orders, and sources of the harmonics. Then, a two-dimensional motor model is established using ANSYS electromagnetic field simulation software to investigate the temporal and spatial characteristics of electromagnetic force waves under both no-load and on-load conditions. Fourier decomposition is applied to obtain the amplitude-frequency characteristics, thereby verifying the correctness of the analytical results. Subsequently, three-dimensional models of the stator core and the complete stator assembly are constructed in the physical field, and their modal frequencies and mode shapes are obtained through simulation. On this basis, harmonic response analysis is conducted by applying electromagnetic force waves to the stator teeth, and vibration simulations are performed in ANSYS Workbench to acquire vibration characteristics. Vibration experiments are then carried out at multiple rotational speeds, and the experimental results are compared with the simulation results to validate the feasibility and accuracy of the finite element modeling approach. Since the measured motor vibration results are influenced not only by electromagnetic excitation forces, but also by various factors such as mechanical structure, instrument installation, and fixture conditions, while the simulation model in this paper inevitably simplifies damping, housing details, inverter control effects, and considers only the effect of radial electromagnetic forces, there exists a certain discrepancy between the simulated and measured motor vibration acceleration results. However, the main vibration trends in the low-frequency range below 800 Hz are basically consistent, particularly at the second and fourth harmonic frequencies, where the vibrations are electromagnetic vibrations caused by radial electromagnetic force waves, with relative errors between the measured and simulated values of 18% and 25%, respectively. This finite element model can be used for preliminary design evaluation of PMSMs and rapid prediction of electromagnetic vibration, providing researchers with a convenient and practical research approach and methodology. Finally, by analyzing factors that may influence motor vibration, this paper proposes design modifications to the stator structure and air-gap width, providing an optimized solution for reducing electromagnetic vibration of the permanent magnet synchronous motor and avoiding resonance.