This article proposes loss and thermally optimized copper and aluminum structures for automotive electrical machines. A first batch of multiphysics optimization is performed parametrically for six different electrical conductor topologies. Then, a multiphysics—thermal and electromagnetic—hybrid parametric and topology optimization coupled with multiobjective differential evolution (MODE) and with an additional step of local search (LS) is proposed. The introduced topology optimization (TO) algorithm is explained in detail and applied to optimize electrical conductor geometries of pure Cu and AlSi10Mg. After that, the manufacturing by additive manufacturing (AM) of the most promising model is presented. The produced topology is benchmarked against a well-known fully rectangular structure. The proposed topology-optimized geometry has been found to improve conventionally manufactured electrical conductors at intermediate frequencies, around 600–800 Hz, and improves considerably at high frequencies, achieving a reduction in losses of 58% at 2000 Hz compared to a conventional rectangular copper structure.


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    Title :

    Multiphysics Topology Optimization of Aluminum and Copper Conductors for Automotive Electrical Machines




    Publication date :

    2024-12-01


    Size :

    2547391 byte




    Type of media :

    Article (Journal)


    Type of material :

    Electronic Resource


    Language :

    English



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