Thermal-Electrical-Vibration Coupling Analysis and Lightweight Structure Optimization of High Power Density Flux-Switching Permanent Magnet Linear Motors

This paper presents a comprehensive framework for thermal-electrical-vibration coupling analysis and lightweight structure optimization of high power density flux-switching permanent magnet linear motors (FSPMLMs). A multi-physics finite element model integrating electromagnetic, thermal, and structural fields is established to investigate the complex interactions between these domains under high power density operation. The electromagnetic-thermal coupling analysis reveals nonlinear temperature rise patterns with distinctive hotspots in winding regions, while the electromagnetic-vibration coupling identifies critical correlations between thrust fluctuations and structural responses. Topology optimization methods are implemented to achieve significant mass reduction while preserving essential performance characteristics, with the bidirectional evolutionary structural optimization approach achieving 22.4% weight reduction. The impact analysis of lightweight structures on coupling characteristics identifies critical regions where material distribution significantly affects multiple performance metrics. The developed methodology provides valuable insights for high-performance electromagnetic actuator design where power-to-weight ratio represents a critical performance metric.