CAREER: An Inclusive Approach to Diversity Inspired Design on Novel 3D Printed Electric Motors

职业生涯：新型 3D 打印电动机的多样性启发设计的包容性方法

• 批准号: 2045776
• 负责人: Shanelle Foster
• 金额: $ 50万
• 依托单位: Michigan State University
• 依托单位国家: 美国
• 项目类别: Continuing Grant
• 财政年份: 2021
• 资助国家: 美国
• 起止时间: 2021-02-15 至 2026-01-31
• 项目状态: 未结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2045776&HistoricalAwards=false
• 关键词: CAREER; Inclusive; Approach; Diversity; Inspired

Electric motors are widely used in all of the economic sectors that contribute to greenhouse gas emissions. Improvements in efficiency and power density of electric motors can reduce the amount and types of pollutants emitted into the environment. Manufacturing design modifications aimed to improve the performance of electric motors can be a nightmare with conventional manufacturing techniques. 3D printing technologies offer unique versatility in size, shape and diversity of materials, promoting flexibility in motor design that is presently unavailable with conventional manufacturing technologies. To create the next generation of high performance electric motors, 3D printing can be used to strategically deposit material during motor manufacturing similar to the way spiders strategically deposit silk in key areas to optimize web design. Spiders use diversity in web silks to build a more structurally sound web. The variability of the silk properties is the strength of the web and enable it to perform its intended task more efficiently. Likewise, 3D printing allows motor designers to manufacture lightweight, robust motors, which can significantly reduce the emissions of greenhouse gases, which is key to preserving the environment. This proposed project aims to stretch the imagination beyond conventional electric motor design to inform creation of new design rules and materials by adopting aspects of the inclusion based diversity in design used by spiders. The proposed project extends inclusion-based diversity to strengthen the pipeline of talent in engineering as well. An integral part of the proposed project includes faculty-mentored undergraduate research experiences for underrepresented minorities and women, as well as, development of inexpensive, project-based, pre-college basic physics courses for both in-person and virtual delivery. Virtual delivery will facilitate participation of students from underserved domestic communities and those on other continents. Electric motor performance is dependent upon its design, properties of its materials and the processes used in manufacturing. Conventional manufacturing techniques place a ceiling on power density and inhibits production of more compact motor designs. Moreover, the inclusion of intricate design features that enhance motor performance is complex with conventional (subtractive and powder metallurgy) techniques. 3D printing (additive manufacturing) can potentially overcome many of the challenges that currently limit realization of many novel electrical machine designs. This proposed project will consider the capabilities of 3D printing, which mimic the intuits of a spider, which include material diversification, consideration for resources and environment as well as optimization of energy input without sacrificing functionality. The specific research goals of the proposed project are to rethink the use of homogeneous electrical steel in the design of stators and rotors and explore the capabilities of non-homogenous electrical steels for multi-material 3D printed magnetic cores. Topology optimization techniques are excellent options for exploring this uncharted territory; however, a model of the electric motor is required for accurate computation of the machine performance characteristics. Subdomain models will be developed to include local and spatial material heterogeneities. Each subdomain will include variations in thermal, mechanical, electrical and magnetic properties of the material (magnetic, conductive and dielectric). Exploration of optimization algorithms, including social spider optimization, genetic algorithms, and gradient methods, is required to select the algorithm that best handles multiple objectives, multiple variables, and multiple physics. Regression analysis, sensitivity analysis and analysis of variance will extract new design rules. Additive manufacturing processes in design of electric motors have not been adequately explored in literature or the engineering industry. The research activity will provide a broad knowledge base and advance the development of electric machines that capitalize on the benefits of additive manufacturing without sacrificing performance.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

电动机广泛应用于所有产生温室气体排放的经济部门。电动机效率和功率密度的提高可以减少排放到环境中的污染物的数量和种类。对于传统的制造技术来说，旨在提高电机性能的制造设计修改可能是一场噩梦。3D打印技术在尺寸、形状和材料多样性方面提供了独特的多功能性，促进了电机设计的灵活性，这是目前传统制造技术无法实现的。为了制造下一代高性能电动机，3D打印可用于在电机制造过程中战略性地沉积材料，类似于蜘蛛在关键区域战略性地沉积丝以优化网页设计的方式。蜘蛛利用蛛丝的多样性来构建结构更完善的网。丝特性的可变性是网的强度，使它能够更有效地执行其预期的任务。同样，3D打印允许电机设计师制造轻质，坚固的电机，这可以显着减少温室气体的排放，这是保护环境的关键。这个提议的项目旨在超越传统的电动机设计，通过采用蜘蛛设计中基于包容性的多样性方面，为新的设计规则和材料的创造提供信息。拟议的项目扩展了基于包容性的多样性，以加强工程人才的储备。拟议项目的一个组成部分包括为代表性不足的少数民族和妇女提供教师指导的本科生研究经验，以及开发廉价的、基于项目的大学预科基础物理课程，包括面对面和虚拟授课。虚拟交付将促进来自服务不足的国内社区和其他大洲的学生的参与。电动机的性能取决于它的设计、材料的特性和制造过程。传统的制造技术限制了功率密度，抑制了更紧凑的电机设计的生产。此外，包括复杂的设计特点，提高电机性能是复杂的传统（减法和粉末冶金）技术。3D打印（增材制造）可以克服目前限制许多新型电机设计实现的许多挑战。这个提议的项目将考虑3D打印的能力，它模仿蜘蛛的直觉，包括材料多样化，对资源和环境的考虑，以及在不牺牲功能的情况下优化能源输入。该项目的具体研究目标是重新思考均质电气钢在定子和转子设计中的使用，并探索非均质电气钢用于多材料3D打印磁芯的能力。拓扑优化技术是探索这一未知领域的绝佳选择；然而，为了准确计算机器的性能特性，需要电动机的模型。子域模型将被开发以包括局部和空间的材料异质性。每个子域将包括材料（磁性、导电性和介电性）的热、机械、电和磁性的变化。需要探索优化算法，包括社交蜘蛛优化、遗传算法和梯度方法，以选择最好地处理多目标、多变量和多物理的算法。回归分析、敏感性分析和方差分析将提炼出新的设计规律。在电机设计中的增材制造工艺在文献或工程行业中尚未得到充分的探讨。这项研究活动将提供广泛的知识基础，并在不牺牲性能的情况下，推动利用增材制造优势的电机的发展。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

项目成果

Improving the soft magnetic properties of binder jet printed iron-silicon alloy through boron addition

添加硼提高粘合剂喷射印刷铁硅合金的软磁性能

• DOI: 10.1016/j.matchemphys.2022.127181
• 发表时间: 2023
• 期刊: Materials Chemistry and Physics
• 影响因子: 4.6
• 作者: Kumari, Geeta;Pham, Thang Q.;Suen, Hawke;Rahman, Tanzilur;Kwon, Patrick;Foster, Shanelle N.;Boehlert, Carl J.
• 通讯作者: Boehlert, Carl J.

Optimal design of electric machine with efficient handling of constraints and surrogate assistance

• DOI: 10.1080/0305215x.2022.2152805
• 发表时间: 2022-06
• 期刊: Engineering Optimization
• 影响因子: 2.7
• 作者: Bhuvan Khoshoo;Julian Blank;Thang Q. Pham;K. Deb;Shanelle N. Foster

Harmonic Utilization Permanent Magnet Topology Design Considerations

谐波利用永磁拓扑设计注意事项

• DOI: 10.1109/icecet58911.2023.10389458
• 发表时间: 2023
• 期刊: IEEE
• 作者: Madovi, Orwell;Khoshoo, Bhuvan;Foster, Shanelle N.
• 通讯作者: Foster, Shanelle N.

Multi-permeability optimization approach for the iron core of a synchronous reluctance machine - an application of additive manufacturing

同步磁阻电机铁芯多重磁导率优化方法——增材制造的应用

• DOI: 10.1109/ecce47101.2021.9595987
• 发表时间: 2021
• 期刊: 2021 IEEE Energy Conversion Congress and Exposition (ECCE
• 作者: Pham, Thang Q.;Foster, Shanelle N.
• 通讯作者: Foster, Shanelle N.

Eddy Current Loss Reduction in Binder Jet Printed Iron Silicon Cores

减少粘合剂喷射印刷硅铁芯中的涡流损耗

• DOI: 10.1109/icem51905.2022.9910749
• 发表时间: 2022
• 期刊: 2022 International Conference on Electrical Machines (ICEM
• 作者: Khoshoo, Bhuvan;Islam, Khan Jazib;Suen, Hawke;Kwon, Patrick;Lozano, Jorge Pena;Foster, Shanelle N.
• 通讯作者: Foster, Shanelle N.