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This paper proposes a combined electromagnetic and mechanical topology optimization for weight reduction in electrical machines based on Finite Element Analysis (FEA) and Evolutionary Structural Optimization (ESO). The devised method is an on- off-type algorithm with adaptative mesh in which low flux density and low Von Mises stress cells are removed successively from a first machine design. With this approach, the weight of the machine can be considerably reduced without compromising the electromagnetic performance of the machine, with a reduced computation time compared to other topology optimization methods. A case study involving a 1.2 MW low-speed, permanent magnet motor is analyzed under different conditions (algorithm parameters, initial mesh, rotational speed) and used to compare the proposed method with two other topology optimization approaches.

Novel Topology Optimization Method for Weight Reduction in Electrical Machines