Vibration analysis of permanent magnet synchronous motor using coupled finite element analysis and optimized meshless method

Conventional finite element analysis (FEA) performed in electromagnetic-vibration coupling calculation of motor suffers from several significant drawbacks, such as large memory space, high computational cost and heavy reliance on mesh quality for accurate solution. With the traditional meshless method, special attention needs to be paid to correctly impose the boundary condition like FEA. Besides, the matrix is easily prone to be ill-conditioned due to introducing large amount of higher-order basis functions. We propose a novel multi-physical coupling method combining FEA and optimized meshless method. The proposed methodology is further evaluated on the vibration analysis of a 12-slot 10-pole permanent magnet synchronous motor (PMSM). Firstly, 2D stator electromagnetic force is simulated and derived based on the local Jacobian derivative method through FEA. The electromagnetic force spectrum is calculated using FFT analysis and further imported into commercial meshless structural simulation software SimSolid for stator harmonic response analysis. Correct force boundary condition and data mapping between meshless and FEA simulation interface are key to the accuracy of the proposed combined multi-physical modeling methodology. This is achieved by introducing new high-dimensional ramp function in the transition region between FEA and meshless domains, which are defined with the shape functions composed of the FEA and meshless method. This function satisfies the continuity and consistency of the displacement function and ensures the convergence of coupled FEA-meshless method. Subsequently, construction of basis function is key to the establishment of convention meshless discrete equation for the elastic problem of rotating machinery. This is designed by using moving least square theory in cylindrical coordinate system. A harmonic response with meshless method is analyzed by using the mode superposition method to obtain detailed mode shape data, acceleration and displacement distribution of stator. Finally, the tangential continuity and robustness are not well considered in the traditional simulation with FEA coupled meshless method. To mitigate this problem, we propose an optimized meshless method based on modified local basis functions to recalculate the harmonic response motion. Then, the coupling electromagnetic-vibration simulation results of traditional coupled FEA-meshless method, optimized coupled FEA-meshless method and complete FEA coupled method are compared. It is worth noting that the optimized method significantly improves accuracy, robustness and computational speed at the same time. In short, the proposed electromagnetic-structure coupling calculation method provides a novel alternative for the multi-physical coupling calculation of rotating machinery combining FEA and meshless simulation methods.