Robust topology optimization of electric machines using topological derivatives

Abstract Designing high-performance electric machines that maintain their efficiency and reliability under uncertain material and operating conditions is crucial for industrial applications. In this paper, we present a novel framework for robust topology optimization with partial differential equation constraints to address this challenge. The robust optimization problem is formulated as a min-max optimization problem, where the inner maximization is the worst case with respect to predefined uncertainties, while the outer minimization aims to find an optimal topology that remains robust under these uncertainties using the topological derivative. The shape of the domain is represented by a level set function, which allows for arbitrary perturbation of the domain. The robust optimization problem is solved using a theorem of Clarke to compute subgradients of the worst case function. This allows the min-max problem to be solved efficiently and ensures that we find a design that performs well even in the presence of uncertainty. Finally, numerical results for a two-material permanent magnet synchronous machine demonstrate both the effectiveness of the method and the improved performance of robust designs under uncertain conditions.