Optimization of Mass and Dimensional Indicators of an Alternating Current Commutator Motor Using Experimental Design

One of the important tasks in the development of AC commutator motor for manual power tool drive is to reduce their mass and dimensional indicators while maintaining acceptable energy performance. The solution of this problem allows us to reduce the cost of production and improve ergonomic qualities. This article discusses the problem of optimizing the consumption of active materials in an AC commutator motor for driving an angle grinder. To accomplish this task, the method of a complete factorial experiment of the form 2 3 was applied. As varied factors were the number of the armature winding wires, the number of the excitation winding turns and the stator and armature magnetic core length. The response functions were the winding wire and electrical steel masses, efficiency, power factor and rotation speed. To perform a computational experiment, an application program developed by the author for electromagnetic calculation of an AC commutator motor, having a modular structure, was used. Based on experiment results, the regression equations were compiled, connecting factors and response functions. The optimization of the mass and dimensional indicators of the AC commutator motor was made graphically in several stages with limitations on efficiency, power factor and rotation speed. As a result, new optimal values of the winding data and the length of the magnetic core were obtained. The results of the calculation of the optimized AC commutator motor using the named application program confirmed acceptable energy performance and rotational speed while reducing the consumption of active materials by 5-6%.