Robust optimization design of permanent magnet synchronous motors for a solar airplane based on a lightweight structure

Due to the characteristics of high-altitude solar airplanes, the permanent magnet synchronous motors (PMSMs) require not only high torque density, but also high reliability. The balance of quality, reliability, and performance in a design proposal is particularly important. In this paper, a robust mechanical–electrical integrated optimization method for PMSMs based on 6σ theory is proposed. According to the fatigue characteristics of materials under the propeller working conditions and the uncertainty factors caused by the actual machining dimension tolerance, the electromagnetic dimension, mechanical dimension and reliability of the PMSM are connected. And a robust optimization model for the reliability and performance of the PMSMs is established. The Monte Carlo method and finite element simulation method are used to verify the correctness of the established optimization model. According to the comparison between the deterministic optimization method and the proposed optimization model, this method can significantly improve the output performance and reliability of the PMSMs.