Motor structure design based on power density target and manufacturability

因著全球暖化、能源危機的威脅，進入了電動車輛蓬勃發展的新時代，對於車用動力馬達性能要求逐漸提高，其中功率重量密度與功率體積密度為關鍵的重要指標。以傳統的馬達結構設計流程方法進行馬達結構設計，不僅僅在功率密度目標上常無法有效達成，也因為結構設計的結果在可製造性上產生問題，導致整個流程不斷產生設計迴圈，使設計工作的效率低落。 因此本研究針對傳統馬達結構設計流程方法進行問題探討與分析，建構了創新的馬達結構設計流程方法，以整合演化式結構最佳化(ESO)方法與基於功率體積密度之馬達結構材料設置、馬達結構材料分佈最佳化、馬達機構分件與材料配置幾何匹配、基於功率重量密度之分件重量配置與初步結構設計，為一演化式馬達結構最佳化(EMSO)設計流程方法，搭配在結構細部設計中考慮馬達可製造性設計，使得此創新的馬達結構設計流程方法，可以有效的達成功率密度目標，並使結構設計結果具備可製造性。 實務應用在FORMOSUN先進動力研究中心所開發的電動車輛平台Green Jumper之動力馬達結構設計上，不僅較傳統設計流程所設計的馬達提升25.6%功率重量密度，與10%功率體積密度之性能，更使得結構設計的結果通過可製造性判定，並且整個流程完全沒有任何設計迴圈之產生，可以說是極為有效地提升設計工作的效率，解決了傳統馬達結構設計流程之問題。Because of global warming and energy shortage crisis, it is entering the electric vehicle vigorous development new time. So the performance requirements for vehicle motor gradually increase, and the power weight and volume density is key and important indicator. The motor structure traditional design method not only makes the power density cannot effectively be reached, but also have problems in manufacture. It causes the entire flow to produce unceasingly design circle, and makes the project work efficiency to be low. Therefore this research carries on the question discussion and the analysis in the traditional motor structural design method. This research also constructs the innovation motor structural design method, include Evolutionary Structural Optimization (ESO), establishment of motor structural material based on of power volume density, the motor structural material distribution optimization, motor mechanism design with the material disposition geometry match, and the weight disposition and preliminary structural design based on the power weight density. The integration of these processes is named Evolutionary Motor Structural Optimization (EMSO). EMSO can effectively achieve the power density goal, and makes the structural design result has the manufacturability. The practice application in motor structural design of electric vehicle platform, Green Jumper, which the FORMOSUN advanced power research center developed, not only promote 25.6% power weight density and 10% power volume density, compared to traditional design method, but also make the structural design result passed the manufacturability determination. And the entire flow does not have any design circle. This research result can promote the project work efficiency, and solve problems in the traditional motor structural design flow