Optimized 3D printed reluctance rotor

Result code in IS VaVaI

<a href="https://www.isvavai.cz/riv?ss=detail&h=RIV%2F49777513%3A23220%2F25%3A43978261" target="_blank" >RIV/49777513:23220/25:43978261 - isvavai.cz</a>

Result on the web

<a href="http://partnerstvi.fel.zcu.cz/vysledky/" target="_blank" >http://partnerstvi.fel.zcu.cz/vysledky/</a>

DOI - Digital Object Identifier

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Result language

angličtina

Original language name

Optimized 3D printed reluctance rotor

Original language description

This research report focuses on the design, optimization, and experimental evaluation of an additively manufactured rotor for a synchronous reluctance machine. Conventional reluctance rotors, typically composed of axially stacked electrical steel sheets, restrict the achievable geometry of flux barriers and end-bridge structures, limiting potential improvements in torque performance and torque ripple reduction. In this work, a finite element model of a reference Siemens SynRM is developed in both COMSOL Multiphysics and Ansys to ensure modelling robustness. Several topology optimization strategies are implemented, targeting increased average torque and reduced torque ripple while maintaining mechanical feasibility. A Helmholtz-filtered SIMP-based material interpolation and MMA optimization scheme is applied to generate new rotor topologies, including variants with and without end bridges. The optimized 2D designs are post-processed, smoothed, and merged into a segmented 3D rotor suitable for additive manufacturing. The resulting topology enables partial elimination of end bridges and axial variation of structural segments. Comparative simulations demonstrate notable improvements in torque characteristics relative to the original rotor. The final rotor is fabricated via additive manufacturing and assembled into the reference machine for subsequent measurement and validation.

Czech name

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Czech description

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Type

O - Miscellaneous

CEP classification

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OECD FORD branch

20201 - Electrical and electronic engineering

Project

<a href="/en/project/TN02000028" target="_blank" >TN02000028: Center for advanced machines and manufacturing technology</a><br>

Continuities

P - Projekt vyzkumu a vyvoje financovany z verejnych zdroju (s odkazem do CEP)

Publication year

2025

Confidentiality

C - Předmět řešení projektu podléhá obchodnímu tajemství (§ 504 Občanského zákoníku), ale název projektu, cíle projektu a u ukončeného nebo zastaveného projektu zhodnocení výsledku řešení projektu (údaje P03, P04, P15, P19, P29, PN8) dodané do CEP, jsou upraveny tak, aby byly zveřejnitelné.