Parametric Modeling and Sensitivity Analysis of a Hairpin Winding Permanent Magnet Synchronous Motor for Robust Design Optimization

Aiming at the robust optimization design of a hairpin winding permanent magnet synchronous motor, the parametric modeling and sensitivity analysis are carried out considering manufacturing uncertainties. To consider the impact of manufacturing uncertainties more comprehensively in the motor design stage, a parametric model of the hairpin winding permanent magnet synchronous motor is developed considering both the geometric structure tolerance and property inconsistency. Then, sensitivity analysis of the design parameters is carried out to find the key parameters that have dominant influences on motor performance. To save the calculation time, the approximate model with a multi-level analysis strategy is used to quickly calculate the model response under different input parameters. Afterward, the proper modeling method is investigated to ensure robust optimization results validity with limited information on manufacturing uncertainties. Finally, the parameters that have dominant influences on motor performances and the performances that are susceptible to manufacturing uncertainties are identified.