Formal design optimization of PM drive couplings

Permanent magnet drive couplings are used to transmit power from the prime mover to the load in a wide range of industrial applications such as fans and blowers. Formal design optimization techniques are explored for improving the coupling designs. A standard coupling design is used to define the base performance constraints and new coupling designs are developed which reduce manufacturing costs by minimising the total active and the magnet material volumes. Alternative designs including the use of lower cost aluminium conductor material and the removal of the steel backing iron are also presented. Different optimization methods (direct, genetic and hybrid) are investigated with a view to use as a general everyday design tool.