Model-based assembly optimization for the automation of electric drive production with minimum unbalance

建议项目应详细说明电动机转子是否可以通过模型和易于测量的参数来描述，以便智能装配策略可以通过优化装配显著降低转子的初始不平衡。由于旋转电机的广泛应用，这个问题变得越来越重要，旋转电机的服务范围从仅几瓦功率的微型电机到牵引驱动装置，最后是几兆瓦功率的大型电机[1]。对于几乎所有的应用，电动机的转子必须在单独的非增值过程中进行平衡[2]。平衡过程将惯性轴与旋转轴对齐，从而减少不必要的振动。以前的研究主要涉及新平衡方法的开发和现有平衡方法的改进。然而，很少有人研究如何通过优化装配来预测转子的不平衡和避免不平衡质量。到目前为止，还没有研究通过已知易于测量的变量（例如所附磁体的重量）来预测由多个单独部件组成的刚性转子的不平衡程度。设想的工作应能够描述永磁同步电机（PMSM）的转子，并在模型中考虑单个组件的生产影响，从而计算产生的不平衡。在此基础上，提出了一种基于模型的在线优化算法，该算法将显著降低转子装配过程中的不平衡，如果该方法能够得到验证，将对部件质量（制造偏差和装配偏差）及其对不平衡的影响有新的认识。通过在工业上的应用，这些新知识可以提高电机的生产质量，降低成本。如果应用于汽车行业，节省的成本，时间和精力以及质量的提高将对动力总成的电气化产生积极的影响。

The proposed project shall elaborate on the question whether the rotor of an electric motor can be described by a model and easily measurable parameters in a way that intelligent assembly strategies can significantly reduce the initial unbalance of the rotor through optimized assembly. This issue is gaining in relevance due to the wide range of application of rotating electric machines whose range of services goes from micro-motors with just a few watts of power to traction drives and finally big motors with a power of several megawatts [1]. For nearly all applications, the rotors of electric motors must be balanced in a separate and non value adding process [2]. The balancing procedure aligns the inertia axis with the rotation axis, thus, reducing the undesired vibrations.Previous research has in particular dealt with the development of new balancing methods and the improvement of existing ones. However, very little research has been done to predict the imbalance and to avoid unbalanced masses by an optimized assembly.So far, no investigations have been conducted on to what extend the imbalance of a rigid rotor consisting of several individual components can be predicted by knowing the variables that are easy to measure (e.g. the weight of attached magnets). The envisaged work shall result in the ability to describe the rotor of a permanent magnet synchronous motor (PMSM) with the production impact of individual components in a model, allowing the calculation of the resulting imbalance. On this basis, a model-based online optimization algorithm can be developed that will significantly reduce the imbalance during rotor assembly.If this new approach can be validated, new findings will be obtained on component quality (manufacturing variances and assembly variations) and its contribution to the imbalance. With its application in industry, this new knowledge could increase the production quality of electric motors and reduce the costs. If applied in the automotive industry, the savings in cost, time and effort as well as the quality improvements would have a positive impact on the electrification of the powertrain.