Acoustic Noise Reduction in an 8/6 Switched Reluctance Machine using Structural Design

Abstract

Switched reluctance motors (SRMs) possess many desirable qualities for the long-term sustainability of electrified transportation such as cheap production costs and simple, robust configurations. However, high acoustic noise and torque ripple are two performance imperfections that have prevented the widespread implementation of SRMs. This thesis investigates design techniques to reduce the acoustic noise produced by an 8/6 SRM while also analyzing the impact each design has on the motor’s performance. The fundamentals of SRMs are discussed including the operating principles, modelling and control strategies. The multiphysics finite element analysis (FEA) toolchain used to accurately model acoustic noise and vibrations of SRMs is described. Using the network of FEA tools, nodal forces and natural frequencies of a four phase 8/6 SRM are analyzed to study the acoustic noise and vibration behaviours. The FEA process is validated experimentally by matching measured vibration modes and acoustic noise sound pressure level (SPL) with FEA numerical results. Through inspiration from an extensive literature review, various design techniques are applied to a baseline four phase 8/6 SRM and compared for both acoustic noise reduction and EM performance criteria. The investigated designs were split into two categories, stator-housing modifications that aim to increase the stiffness of the assembly and rotor modifications that aim to reduce the magnitude of radial forces while preserving performance. The best design strategies as determined by the comparative analysis were then further optimized to combine the best techniques together for the 8/6 SRM. The proposed structural improvements included the modifications of the stator yoke shape along with increasing the number of fastening components involved in the assembly. Additionally, an iterative procedure for the parametric modelling of windows introduced to the rotor poles is outlined. The best design considerations are combined to create the design of a novel 8/6 SRM which significantly reduces the acoustic noise produced by the motor with little impact to performance.