Abstract:

We present a simultaneous magnetic-structural topology optimization of a synchronous reluctance motor (SynRM) rotor to maximize average torque while enforcing torque ripple and rotor stiffness constraints. Nonlinear magnetic behavior is captured using cubic-spline interpolation of the B - H curve of electrical steel lamination, and design-dependent centrifugal rotor loads are parameterized using density design variables. A multi-stage continuation strategy mitigates the design oscillation between torque-focused and stiffness-focused layouts. Numerical results show the trade-off between electromagnetic performance and mechanical robustness, with final design achieving up to 14% higher average torque, up to 3% lower mass, and significantly reduced torque ripple relative to the baseline design.