Performance Assessment and Design Optimization of Linear Synchronous Motors for Manufacturing Applications
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The major contributions of this thesis are categorized into three areas: (i) magnetic modeling, (ii) optimal performance assessment and (iii) multi-objective design methodology of the linear permanent-magnet (LPM) and linear variable reluctance (LVR) motors for manufacturing automation applications. The target application is to perform repetitive point-to-point positioning tasks on a continuous basis under temperature constraints. Through simplification, the constraint on temperature rise may be replaced by a constraint on average power dissipation, provided that the thermal resistance is constant and known. The basic framework of analysis is first introduced for a class of idealized linear synchronous (LS) motors, where magnetic saturation and spatial harmonics are neglected, to provide clarity and insight. The physics-based force models for the LPM and LVR motors, including spatial harmonics and magnetic saturation as appropriate, are then developed. Due to magnetic linearity, the force model of the LPM motor is derived from the analytical solution of the Poisson Equation. A nonlinear magnetic circuit analysis model is developed for the LVR motor that includes both spatial harmonics and magnetic saturation. The accuracy of both force models are verified by finite element analysis. Applying those force models, the optimal performance assessment of the LPM and LVR motors is explored using the mathematical framework discussed for the idealized LS motors. In particular, the relationship between travel time and travel distance is characterized in terms of average power dissipation. The performance assessment methodologies developed here may be applied to any motor technology used in manufacturing automation applications. The multi-objective design optimization problem is then defined and software for its solution is developed using Monte-Carlo synthesis, the performance assessment tools and dominance-based sorting. Design results for the LPM and LVR motors are then presented. Future research is discussed as the conclusion of the thesis.