Optimization of a 3D-Printed Permanent Magnet Coupling Using Genetic Algorithm and Taguchi Method

In recent decades, the genetic algorithm (GA) has been extensively used in the design optimization of electromagnetic devices. Despite the great merits possessed by the GA, its processing procedure is highly time-consuming. On the contrary, the widely applied Taguchi optimization method is faster with comparable effectiveness in certain optimization problems. This study explores the abilities of both methods within the optimization of a permanent magnet coupling, where the optimization objectives are the minimization of coupling volume and maximization of transmitted torque. The optimal geometry of the coupling and the obtained characteristics achieved by both methods are nearly identical. The magnetic torque density is enhanced by more than 20%, while the volume is reduced by 17%. Yet, the Taguchi method is found to be more time-efficient and effective within the considered optimization problem. Thanks to the additive manufacturing techniques, the initial design and the sophisticated geometry of the Taguchi optimal designs are precisely fabricated. The performances of the coupling designs are validated using an experimental setup.