NVH multiobjective and robust optimization of electric motor design, including power losses

As part of electric motor design, compromises between NVH considerations, electrotechnical design and performance targets must be made. Electromagnetic excitation within the airgap results in structure-borne and airborne noise transmission to the vehicle. High-frequency tones are characteristic of this noise. Efficient computation methods exist to estimate these vibration and noise levels. From the early design stage, NVH performance can be diagnosed and optimized. The focus on NVH can no longer be separated from efficiency optimization. Simulation workflows and optimization loops, developed for NVH-related targets, are updated to consider copper and iron losses. The modification of the geometrical design must be addressed to reduce both dynamic excitation and energy loss, or at least offer compromises. Electric motor design optimization requires the handling of multiple objectives and constraints from multiple physics. In addition, design robustness must be ensured as part of the industrial process: manufacturing tolerances have to be considered to define a robust optimized design.