Surrogate Vibration Modeling Approach for Design Optimization of Electric Machines

The transportation sector is undergoing electrification to gain advantages such as lighter weight, improved reliability, and enhanced efficiency. As contributors to the safety of embedded critical functions in electrified systems, better sizing of electric machines in vehicles is required to reduce the cost, volume, and weight. Although the designs of machines are widely investigated, existing studies are mostly complicated and application-specific. To satisfy the multi-level design requirements of power systems, this study aims to develop an efficient modeling method of electric machines with a background of aircraft applications. A variable-speed variable-frequency (VSVF) electrically excited synchronous generator is selected as a case study to illustrate the modular multi-physics modeling process, in which weight and power loss are the major optimization goals. In addition, multi-disciplinary design optimization (MDO) methods are introduced to facilitate the optimal variable selection and simplified model establishment, which can be used for the system-level overall design. Several cases with industrial data are analyzed to demonstrate the effectiveness and superior performance of the modeling method. The results show that the proposed practices provide designers with accurate, fast, and systematic means to develop models for the efficient design of aircraft power systems.

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Control and Design Optimization of a Novel Hybrid Electric Powertrain System

Volume 2: Mechatronics; Estimation and Identification; Uncertain Systems and Robustness; Path Planning and Motion Control; Tracking Control Systems; Multi-Agent and Networked Systems; Manufacturing; Intelligent Transportation and Vehicles; Sensors and Actuators; Diagnostics and Detection; Unmanned, Ground and Surface Robotics; Motion and Vibration Control Applications ◽

10.1115/dscc2017-5200 ◽

2017 ◽

Author(s):

Chenyu Yi ◽

Bogdan Epureanu

Keyword(s):

Optimal Control ◽

Design Optimization ◽

Fuel Economy ◽

Optimization Problems ◽

Computational Cost ◽

Electric Machines ◽

Hybrid Electric ◽

Hybrid Electric Powertrain ◽

And Control ◽

Electric Powertrains

Control and design optimization of hybrid electric powertrains is necessary to maximize the benefits of novel architectures. Previous studies have proposed multiple optimal and near-optimal control methods, approaches for design optimization, and ways to solve coupled design and control optimization problems for hybrid electric powertrains. This study presents control and design optimization of a novel hybrid electric powertrain architecture to evaluate its performance and potential using physics-based models for the electric machines, the battery and a near-optimal control, namely the equivalent consumption minimization strategy. Design optimization in this paper refers to optimizing the sizes of the powertrain components, i.e. electric machines, battery and final drive. The control and design optimization problem is formulated using nested approach with sequential quadratic programming as design optimization method. Metamodeling is applied to abstract the near-optimal powertrain control model to reduce the computational cost. Fuel economy, sizes of components, and consistency of city and highway fuel economy are reported to evaluate the performance of the powertrain designs. The results suggest an optimal powertrain design and control that grants good performance. The optimal design is shown to be robust and non-sensitive to slight component size changes when evaluated for the near-optimal control.

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