Design of Magnetic Circuits for Magnetocaloric Refrigeration via Topology Optimization

Magnetocaloric systems are one of the most promising solutions for decarbonizing cooling systems. However, several challenges still prevent the technology to reach large-scale market adoption. Among them the high cost and volume of the systems, mainly caused by the magnetic circuits (MC), are highlighted. Addressing these challenges requires emphasizing the trade-off between augmenting magnetic flux density and reducing the mass and complexity of the MC. This study introduces a topology optimization method focused on crafting an MC that minimizes volume while maximizing magnetic flux density. Additionally, only rectangular prismatic permanent magnet segments, with remanence directions perpendicular to two of the prism faces are allowed. The optimized design exhibits similar volume and magnetic flux density compared to configurations with non-prismatic segments. The optimization substantially lowers manufacturing costs and underscoring the potential of topology optimization methods in overcoming key barriers to the large-scale adoption of magnetocaloric systems.