Topology Optimization Combined with a Parametric Algorithm for Industrial Synchronous Reluctance Motor Design

In this paper, we propose combining topology optimization with a parametric algorithm (TOCPA) to design an industrial synchronous reluctance motor (SynRM) that satisfies super-premium efficiency (IE4). TOCPA consists of two main processes. An improved niching algorithm is proposed as an existing parametric algorithm, and multiple optimal points were identified quickly and effectively within the design range specified by the user. Existing parametric algorithms lack the ability to find unpredictable new optimal shapes; therefore, topology optimization has been added. TOCPA converges the two optimization methods to compensate for the shortcomings of each and maximizes the advantages. In addition, the boundary surface ON–OFF method is applied to accelerate the topology optimization process. Subsequent ratio-based smoothing techniques smooth out discontinuous interfaces and remove clusters to improve the torque characteristics and reduce the manufacturing difficulty. Finally, the torque ripple was reduced using the skew technique, and mechanical stability was confirmed using a stress analysis. An IE4 industrial SynRM was successfully designed using TOCPA.