Multiphysics Optimization Model to Design High-Power Ultra-High-Speed Machine for Portable Mechanical Antenna Application

This paper presents a new Multiphysics optimization strategy to design a high-power ultra-high-speed machine (HPUHSM). The design process of HP-UHSM is highly iterative and requires Multiphysics optimization to deal with different critical design challenges such as windage loss, thermal limit, centrifugal force, and vibration. However, the Multiphysics optimization of HP-UHSM is a challenge due to several design variables and the huge computation cost of finite element analysis (FEA). In this paper, an integrated Multiphysics optimization process is developed using a combined FEA and analytical model, which provides a robust design geometry and significantly reduces the computational cost. The optimization process integrates a parameterized FEA electromagnetic module with analytical models of thermal, structural, and Rotordynamic analysis. Therefore, it can apply multi-disciplinary design constraints from application requirements and the material’s limitations. The optimal result ensures an efficient and feasible design with a high design-safety-margin by considering the Multiphysics mutual influence. To investigate the efficiency of the proposed optimization model, a 2 kW 500 krpm permanent magnet synchronous machine is designed considering some unique requirements of a potable mechanical antenna. The multidisciplinary performance of the designed machine is studied using 3-D FEA and experimental analysis to evaluate the accuracy and computational efficiency of the proposed model. The comparative results confirm that the proposed optimization model can design an efficient and robust HP-UHSM with high accuracy and very low computational cost.