Research On Model Establishment And Optimization Design Of Novel Transverse Flux Permanent Magnet Linear Motor

China-Germany cooperation in smart manufacturing,Industry 4.0 and "Made in China 2025" reflect the importance of Advanced Manufacturing Technology(AMT)industry.China has upgraded the development of AMT industry to a strategic level.Linear motor system is an important part of advanced manufacturing technology and has application value in high-end Computerized Numerical Control(CNC)machine tools and rail transit drives.Compared with the rotator motor system,the linear motor system has a simpler structure,higher positional accuracy,quicker response and lower noise.it's because the conversion mechanism of the rotatory motion to the linear motion is omitted when the linear motor drives the linear motion load.The permanent magnet l inear motor based on high performance rare earth permanent magnet improves the power density,force density and operating efficiency of the linear motor.And applying the transverse magnetic flux structure to the permanent magnet linear motor,the transverse magnetic flux permanent magnet linear motor is obtained with a further achievement of higher power density and the force density.At the same time,because it has the advantage of independent setting of electromagnetic load,it is also more conducive to the highest efficiency design of the motor.Therefore,the transverse flux permanent magnet linear motor has great application value in the field of large-power linear direct drive such as rail transit traction,conveyor belt driving,and linear power generation.At present,a variety of structural types of transverse flux permanent magnet linear motors have been developed to meet the demand in these fields.But so far,the transverse flux permanent magnet linear motor failed to achieve a breakthrough in the high-precision linear direct drive such as the high-end CNC machine tool feed application due to some shortcomings of the motorThe transverse flux permanent magnet linear motor inherits the advantages of the transverse flux structure,but also inherits the following disadvantages:(1)High flux leakage,thus reducing its power factor,and also affecting its power density,force density.and operating efficiency;(2)High force pulsation,which affects its positional accuracy and weakens the inherent high position accuracy of linear motors;(3)The magnetic circuit is complicated and difficult to analyze.The motor with a three-dimensional magnetic circuit usually uses the three-dimensional finite element analysis,which is not only building the model is difficult,but also the analysis and calculation are very time-consuming.It is hard for optimization design and multi-physics coupling simulation analysis.(4)Difficult to assemble,the special three-dimensional magnetic circuit structure of the motor results in production and assembly difficultiesTherefore,based on the investigation of transverse flux permanent magnet linear motor,this paper makes innovation for the motor structure,the analysis model,the optimization design,coupling electronic and magnetic model.The main contents are as follows1.Presentation,structural topology,operation principle and flux leakage analysis of novel transverse flux permanent magnet linear motorsBased on the basic operation principle of the transverse flux permanent magnet linear motor,two novel transverse flux permanent magnet linear motors,the I-Core transverse flux permanent magnet linear motor and E-core transverse flux permanent magnet linear motor,are proposed for the purpose of overcome the shortcoming of traditional transvers flux permanent magnet linear motor such as complex structure and difficult assembly.In this paper,the structural characteristics and operation principle of the new transverse flux permanent magnet linear motor are presented.The advantages of the respective structures of the two novel motors are described in detail.Furthermore,the flux leakage is analyzed,and the flux leakage circuit of the motor is discussed detail.And summarize the main flux leakage of the transverse flux permanent magnet linear motor:permanent magnet leakage and winding leakage.2.Proposal and research of the Schwarz-Christoffel(SC)mapping analysis model of the transverse flux permanent magnet linear motor.In order to overcome the challenges of modeling difficult,analysis and calculation time-consuming,when using the three-dimensional finite element to analysis the motor.And considering that the energy conversion of the motor mainly occurs in the air gap,SC mapping analysis model of the transverse flux permanent magnet linear motor analysis model was and proposed,which is a two-dimension,analysis model with high calculation precision,high speed and it can consider the edge effect,the leakage magnetic field,the distribution of the air gap magnetic field.To establish the SC model of transverse flux permanent magnet linear motor,the linear motor with a 3-dimension should be equivalently simplified to 2-dimension under the premise of ensuring that the air gap magnetic field does not change firstly.And after that the SC model of transverse flux permanent magnet linear motor can be obtained,the SC mapping analysis model of two novel transverse flux linear motors is presented to illustrate the universality of the proposed method in this paper.And The E-Core transverse flux permanent magnet motor was selected for analysis by SC mapping method.the air gap flux density distribution is solved,based on which,the EMF waveform,no-load cogging force waveform and load force waveform are obtained.Finaly,the prototyped E-C.ore transverse flux permanent magnet motor is manufactured and the results are obtained from the experiment and 3D FEM,respectively,which are used to compare with those from SC mapping method.3.Multi-objective optimization design of transverse flux permanent magnet linear motor by coupling SC mapping model and intelligent optimization algorithm.Influence of magnet shape on the cogging force and thrust force are studied by SC mapping method firstly.Then,the sizing equation of the motor is derived,based on which the influence of the motor parameters on the motor performance can be obtained.The motor is a multi-input,multi-output,nonlinearly coupled system,it is difficult to directly obtain the optimal results by separately studying each parameter.At the same time.designing the motor through sizing equation requires estimating the parameters of the motor which relies heavily on the designer's experience.Employing intelligent optimization algorithm to design the motor can find the optimal structural parameters under the motor's corresponding optimization target efficientlY and accurately,which requires less subjective experience from the designer.In this paper,coupling SC mapping method and nondominated sorting genetic algorithm ?(NSGA-11)is proposed and employed to multi-objective optimization design of E-Core transverse flux permanent magnet linear motor.Finally,the Pareto results are obtained and some of them are selected to compare with the 3-dimension FEM.the feasibility and correctness of the proposed optimization method are verified.4.Proposal and research of multi-plane equivalent magnetic network model with flexible mesh method of transverse flux permanent magnet linear motor.In order to further study the overall performance of the transverse flux permanent magnet linear motor,and consider the saturation and calculation speed,multi-plane equivalent magnetic network model with flexible mesh method is proposed in this paper.Firstly,decomposing the transverse magnetic flux permanent magnet linear motor with a three-dimensional magnetic circuit structure into several parts in which the magnetic flux lies largely in planes.Then,each part of the motor is equivalent to a corresponding plane which is meshed to obtain the multi-plane equivalent magnetic network model.And the flexible mesh method is used to change the size of the mesh elements at different positions of the motor to achieve the purpose of increasing the calculation speed as much as possible while satisfying the calculation accuracy.Furthermore,New criteria for judging the convergence of nonlinear iterations is proposed.Finally,the multi-plane equivalent magnetic network model of E-Core transverse flux permanent magnet motor is built and analyzed.The feasibility and accuracy of the multi-plane equivalent magnetic network model is verified by the SC mapping method model,the finite element method and prototype experiment.And the methods mentioned above are compared5.Proposal and research on coupled electric and magnetic model of transverse flux permanent magnet linear motor.The motor control main circuit and the multi-plane equivalent magnetic network model of the transverse flux permanent magnet linear motor are coupled into an electrical loop network by discretizing the differential equation and introducing the controlled source,equivalent resistance and equivalent source.The coupling model of the transverse flux permanent magnet linear motor system is presented,which provides a new dynamic performance calculation method for the transverse flux permanent magnet linear motor system.6.Prototype and experimentThe prototype of novel transverse magnetic flux permanent magnet linear motor is manufactured.The performance parameters such as the back EMF,cogging force,thrust force,position following ability of the prototype were tested and analyzed through performance test.The test results show that the prototype motor has good performance.