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Panagiotis E. Kakosimos, Minos E. Beniakar and Antonios G. Kladas

This paper discusses the application of Taguchi's methodology for optimizing the design of aerospace actuators, specifically focusing on an Induction Machine (IM). The optimization process aims to maximize mean torque and minimize torque ripple, validated through a manufactured prototype. The results demonstrate the effectiveness of the proposed optimization algorithm in meeting the stringent requirements of aerospace applications.

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Tunde Kovacs
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6 views2 pages

Panagiotis E. Kakosimos, Minos E. Beniakar and Antonios G. Kladas

This paper discusses the application of Taguchi's methodology for optimizing the design of aerospace actuators, specifically focusing on an Induction Machine (IM). The optimization process aims to maximize mean torque and minimize torque ripple, validated through a manufactured prototype. The results demonstrate the effectiveness of the proposed optimization algorithm in meeting the stringent requirements of aerospace applications.

Uploaded by

Tunde Kovacs
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Application of Taguchi’s Methodology to Aerospace Actuators Design

Panagiotis E. Kakosimos1,a, Minos E. Beniakar2,b and Antonios G. Kladas3,c


1,2,3
Department of Electrical and Computer Engineering, National Technical University of Athens, 9 Iroon
Polytechneiou Street, Zografou, 157 80, Greece
a
[email protected], [email protected], [email protected]

Abstract. In this paper the application of Taguchi’s methodology to the design of actuators for aerospace
applications is presented. The preliminary design employing time-stepping finite element analysis is carried out in
order to determine actuators basic dimensional and operating characteristics. Configuration considered is
subsequently optimized regarding the mean torque and torque ripple through the application of a specific
optimization procedure employing Taguchi’s methodology. Resulting IM configuration has been validated through
manufactured prototype illustrating the effectiveness of the proposed optimization algorithm.

1. Introduction
Aerospace applications involve high performance actuation systems, because strict specifications govern as well as
safety and reliability issues, demanding special care for the actuator design optimization procedure considering also its
operational characteristics. The existence of two significantly different modes of operation is typical in aerospace
applications [1], [2]. Under emergency circumstances undesirable disturbances are required for safety reasons. Therefore
the optimized performance involves both points of operation. In literature, multiobjective design optimization procedures
exist involving optimum design criteria of actuator geometry [3], [4].
In this paper, an Induction Machine (IM), complying with particular specifications of a typical aerospace application,
is designed through the application of an optimization procedure. Time-stepping Finite Elements (FE) are enlisted
enabling to specify actuator basic features and determine the detailed machine configuration by applying Taguchi’s
optimization methodology enabled the optimal design of the stator configuration in terms of maximizing the mean torque
and minimizing the torque ripple in a particular aerospace application. Resulting IM configuration has been validated
through manufactured prototype.

2. Actuator specifications and preliminary design


The actuator topology has to comply with particular geometrical and electromechanical requirements. Table 1
summarizes actuator’s main specifications and dimensions for two significantly different modes of operation. Such an
extreme difference in machine specifications is common in aerospace applications mainly for safety reasons during
certain manoeuvres lasting short time intervals. In order to determine main actuator dimensions, preliminary analysis has
been carried out considering initially the fundamental design principles.
The preliminary design involves a first step of electromagnetic dimensional analysis by using classical formulae for
the considered specifications, refined through a finite element investigation [5]. Selection of the main configuration
parameters has been equally assisted by previous investigations in this class of problems while appropriate sensitivity
analysis has been operated at the optimization stage. Classical winding configuration, 24 stator and 30 rotor slots has been
finally selected for the 8-pole IM determined mainly by construction limitations as shown in Fig. 1.
Table 1. Main IM Specifications and Dimensions
Parameter Value
Rated torque, Nm / Rated speed, rpm 1.2 / 180
Maximum torque, Nm / Maximum speed, rpm 6.0 / 6000
Maximum outer diameter, mm 90
Maximum length, mm 120
Table 2. Design Variables and Levels (in mm)
A B C
13.01 3.88 2.74
(a) (b)
Fig. 1. (a) Flux density distribution under normal and emergency 13.73 4.09 2.89
operating conditions. (b) Triangular mesh (37000 nodes). 14.45 4.31 3.05
3. Taguchi’s method application
The application of the Taguchi’s methodology to the design of electrical machines provides the capability of
approaching the near optimum settings of the already found design parameters through the classical design [6–8].
3.1 Orthogonal Array Establishment
In order to establish the prerequisite orthogonal arrays of the problem to be solved, Table 2 has to be filled with the
chosen parameters for the machine optimization and their allowable values. The main stator parameters selected under
this stage of optimization are the tooth length, L, the tooth tip width, Wt1, and tooth width, Wt2, noted hereafter as A, B
and C, respectively. The initial values derived from the classical design are typed in bold font.
3.2 Matrix computation
Considering the fact that three parameters with three respective levels have been selected, a standard Taguchi’s
orthogonal array L-9 has to be adopted conducting the required computations focusing on the computation of average
torque, Tm, and the torque ripple, Tr, where torque ripple is defined as the peak-to-peak value. The results from the
conducted computations employing Maxwell’s stress tensor are tabulated in Table 3. The average value of Tm is 1.2 Nm
while the average ripple is calculated to be about 0.0226 Nm, respectively.
Table 3. Results from Taguchi’s Experiments
No. A B C Tm (Nm) Tr (Nm) No. A B C Tm (Nm) Tr (Nm)
1 1 1 1 1.1859 0.0283 6 2 3 1 1.1959 0.0202
2 1 2 2 1.2005 0.0217 7 3 1 3 1.2035 0.0288
3 1 3 3 1.1986 0.0195 8 3 2 1 1.2008 0.0166
4 2 1 2 1.2064 0.0285 9 3 3 2 1.1992 0.0195
5 2 2 3 1.2092 0.0205
4. Results and discussion
4.1 Analysis of Variance (ANOVA)
Fig. 4 depicts the average effect of Tm and Tr, illustrating the impact of the selected design variables. The Analysis of
Variance enables the thorough evaluation of the effect of the various factors on Tm and Tr.

Table 4. Results of ANOVA


Factor A B C
SS (x10-6) 124 56 155
Tm
% 36.89 16.76 46.36
SS(x10-6) 4 157 4
Tr
% 2.64 95.05 2.31
(a) (b)
Fig. 2. Main parameters effect on Tmean (a) and Tripple (b).

(a) (b)
Fig. 3. IM prototype. (a) Stator. (b) Rotor. Fig. 4. Torque ripple after Taguchi’s method application.
4.2 Design parameters selection
Table 4 summarizes the results of the ANOVA. The average torque for both stator geometries depends considerably on
the tooth length, while the cogging torque is affected significantly by the tooth tip width as expected. The combination
A2-B2-C3, is selected because A2 and C3 affect significantly Tm, while, on the other hand B2 element affects
considerably Tr. Fig. 4 shows the torque ripple which is kept in low levels, while Fig. 3 shows the manufactured
prototype.

5. Conclusions
In this paper the application of Taguchi’s methodology to the design of actuators for aerospace applications is
presented. The preliminary design employing time-stepping finite element analysis is carried out in order to determine
actuators basic dimensional and operating characteristics. IM topology considered is subsequently optimized regarding
the mean torque and torque ripple through the application of a specific optimization procedure employing Taguchi’s
methodology. Resulting IM configuration has been validated through manufactured prototype illustrating the
effectiveness of the proposed optimization algorithm.

6. Acknowledgement
The research leading to these results has received funding from the European Union, in the frame of “Clean Sky”
Program, CfP Topic Nbr: JTI-CS-2009-1-SGO-02-010 under grant agreement 255811EMAS within TEIP Consortium
Member.

References
[1] P. Kakosimos, E. Tsampouris, and A. Kladas, “Design Considerations in Actuators for Aerospace Applications,” IEEE Transactions on
Magnetics, in Press.
[2] P. E. Kakosimos, E. M. Tsampouris, and A. G. Kladas, “Aerospace Actuator Design: a Comparative analysis of Permanent Magnet and Induction
Motor configurations,” in 15th IEEE International Conference on Electrical Machines, 2012.
[3] M. Horii, N. Takahashi, and J. Takehara, “3-D optimization of design variables in x-, y- and z-directions of transformer tank shield model,” IEEE
Transactions on Magnetics, vol. 37, no. 5, pp. 3631–3634, 2001.
[4] T. Ohnishi and N. Takahashi, “Optimal design of efficient IPM motor using finite element method,” IEEE Transactions on Magnetics, vol. 36, no.
5, pp. 3537–3539, 2000.
[5] I. Boldea and S. Nasar, The Induction Machines Design Handbook, 2nd ed. CRC Press, 2010, p. 826.
[6] C.-C. Hwang, L.-Y. Lyu, C.-T. Liu, and P.-L. Li, “Optimal Design of an SPM Motor Using Genetic Algorithms and Taguchi Method,” IEEE
Transactions on Magnetics, vol. 44, no. 11, pp. 4325–4328, Nov. 2008.
[7] H. T. Wang, Z. J. Liu, S. X. Chen, and J. P. Yang, “Application of Taguchi method to robust design of BLDC motor performance,” IEEE
Transactions on Magnetics, vol. 35, no. 5, pp. 3700–3702, 1999.
[8] S. Kim, J. Lee, Y. Kim, J. Hong, S. Member, and Y. Hur, “Optimization for Reduction of Torque Ripple in Interior Permanent Magnet Motor by
Using the Taguchi Method,” IEEE Transactions on Magnetics, vol. 41, no. 5, pp. 1796–1799, 2005.

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