An integrated Multi-Physics and transfer path framework for electromagnetic noise prediction in rotary compressors
摘要
This study focuses on the prediction technology of electromagnetic noise in rotary compressors and establishes an analysis framework that integrates multi-software simulations with parallel experimental validation, significantly improving the accuracy and reliability of the simulation results. A magneto-structural-acoustic multi-physics coupling approach is employed. Specifically, the motor’s electromagnetic behavior is analyzed using a 2D finite element (FE) electromagnetic analysis tool; natural frequencies and structural vibration modes are evaluated through a finite element structural analysis platform; and acoustic radiation is simulated using a finite element-based acoustic field solver. The conversion of structural vibration into airborne sound is governed by structural–acoustic coupling. Panels exhibit maximum acoustic radiation efficiency when the excitation wavelength matches the structural bending wavelength. Thus, mode shapes with higher surface velocity and larger radiating areas contribute more strongly to the overall noise. The simulation results are compared with experimental measurements under actual operating conditions to validate the effectiveness and applicability of the proposed modeling technique. The academic outcomes of this study are as follows: (1) a high-precision electromagnetic noise prediction model for rotating machinery is developed, demonstrating strong agreement between simulation and experimental data, laying a solid foundation for future research in this field; (2) the Theory of Transfer Path Analysis (TPA) is introduced to clearly decompose electromagnetic noise into three major influencing paths—electromagnetic excitation sources, structural natural frequency coupling, and airborne acoustic transmission—offering new insights into noise mechanisms and control strategies; (3) rotor dynamic eccentricity is investigated, revealing that sideband noise phenomena are mainly induced by shaft bending and rotor misalignment, thus highlighting the limitations of conventional concentric rotor assumptions and providing guidance for future modeling improvements. Regarding model accuracy validation, finite element simulations of electromagnetic torque ripple, surface flux density, back-EMF, and unit efficiency exhibit deviations within 5% of the measured values. Structural modal analysis also shows excellent correlation, with an average frequency error of -1.83% and a root mean square error of 4.8%. The results of electromagnetic noise analysis reveal prominent vibration noise peaks at 6, 12, 18, and 24 times the fundamental frequency, particularly under high-speed conditions (6000 rpm and 7200 rpm), where the main peak frequency prediction errors are within 1%, demonstrating the high accuracy and reproducibility of the proposed method. The novelties and scientific contributions of this study include the development of an integrated magneto–structural–acoustic multi-physics framework combined with TPA for electromagnetic noise prediction in PMSMs. In summary, the simulation technology developed in this study can be effectively applied during the design phase of electric rotating machines, enabling early-stage acoustic performance prediction, elimination of inferior designs, and reduction of prototyping costs and development time. The proposed methodology possesses significant academic value and practical application potential.