M.

Roohnavazfar
Department of Industrial Engineering,
Sharif University of Technology,
Tehran 11155, Iran

M. Houshmand
Department of Industrial Engineering,
Sharif University of Technology,
Tehran 11155, Iran

R. Nasiri-Zarandi1
Electrical Machines and Transformers
Research Laboratory,
Department of Electrical Engineering,
Amirkabir University of Technology,
Tehran 15916, Iran
e-mail: Rezanasiri.z@aut.ac.ir

M. Mirsalim
Electrical Machines and Transformers
Research Laboratory,
Department of Electrical Engineering,
Amirkabir University of Technology,
Tehran 15916, Iran;
School of Engineering,
St. Marys University,
San Antonio, TX 78228

Using Axiomatic Design

Theory for Selection
of the Optimum Design
Solution and Manufacturing
Process Plans of a Limited
Angle Torque Motor
The brushless dc limited angle torque motor (LATM) has been widely used in areas of
aerospace equipments, robot drives, optical scanning systems and any drive systems that
require limited motion, ranging from the simple ON-OFF servo valves to the accurate
tracking of a reference signal. This paper presents the optimum design procedure of a
brushless direct current LATM to satisfy the functional requirements (FRs) and constraints using Independence axiom in axiomatic design (AD) approach. Also, to select the
best manufacturing process plan, we consider both cost and thermal performance as two
effective criteria, and evaluate available alternatives by computing information content
in Information axiom. Finally, finite element method is employed to validate the results
obtained by optimizations as well as experimental outcomes extracted from the manufactured prototype of the device. [DOI: 10.1115/1.4027969]
Keywords: axiomatic design theory, manufacturing process plan, limited angle torque
motor

Introduction

AD is a structured, rational design method generated to

improve design activities in the various design domains. This
methodology is developed by Suh [1]. Since evaluation of engineering designs in the absence of an underlying science is problematic, AD is especially worthwhile because the design axioms
elevate engineering design to a science, governed by a few basic
rules, from what has been a kind of an art integrated with engineering analysis [2]. When comparing the AD theory with other
design theories, it is clear that one of the most unique features of
AD is its requirement on clearly distinguishing design decisions
into two different kinds with regards to the notions of domain and
layer (hence the 2D design framework). The former is called a
mapping operation from what to how across two neighboring domains, and the latter is called a decomposition operation
from what to what (or how to how) across two adjacent layers
[3]. Literatures offer many applications of AD methodology to
design products, systems, organizations, and software [4]. Linke
and Dornfeld [5] have reduced the gap between tool design and
sustainability considerations by building an axiomatic grinding
process model that can be used for life cycle considerations. Yu
et al. [6] have designed and manufactured the sandwich endplates
whose face and core are made of carbon fiber reinforced composite and honeycomb/foam, respectively. Kulak and Kahraman [7]
have compared the advanced manufacturing systems using fuzzy
and crisp AD. Maldonado et al. [8] have evaluated ergonomic
compatibility for the selection of computer numerical control
(CNC) milling machines using fuzzy AD approach. Brown [9] has
used AD to design of the integrity of shaft surfaces for rotating lip
1
Corresponding author.
Contributed by the Manufacturing Engineering Division of ASME for publication
in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received
September 29, 2013; final manuscript received June 30, 2014; published online
August 6, 2014. Assoc. Editor: Xiaoping Qian.

seals. Heo and Lee [10] have evaluated design of emergency core
cooling systems. These studies show the applicability and benefits
of AD in solving industrial problems.
The LATM is an electromechanical actuator with a limited
rotation of a moving part. It produces torque through a limited
rotation angle normally less than 6180 deg. Depending on applications, the several types of LATMs have been presented. The
main types of LATMs with their constructional descriptions were
listed by Nasiri-Zarandi et al. [11]. LATMs have advantages such
as higher torque/weight ratio, higher reliability, lower cost, accurate positioning capability, and ease of maintenance due to the
elimination of mechanical commutation as well as electronic
switching over conventional motors [12]. Classic design of an
LATM that was done by Nasiri-Zarandi et al. is based on magnetic equivalent circuit (MEC) model [11]. Their performance
prediction as well as design of a wide-angle limited motion rotary
actuator has been presented in Refs. [11], [13], and [14]. An important form of the LATM based on polarized reluctance principle
called Laws relay has been constructed [1521] in which the
design, identification, and performance prediction have been
investigated. Modeling of the Laws relay actuator has been discussed in Refs. [18] and [19]. The application of magnetic fluids
in a hydraulic servo-valve torque motor has been introduced in
Refs. [20] and [21].The design and control of a two-pole toroidally wound armature LATM with application in fuel control of
gas-turbine engines has been presented in Ref. [12]. A brief categorization of electromagnetic actuators based on operating principle, design trade-offs, and material selection has been discussed in
Ref. [22]. The study of permanent magnets PM-assisted devices
based upon MECis also performed in Refs. [23] and [24].
In this paper, AD methodology is applied to design and manufacture of a radial slotless LATM. In this method, the design parameters (DPs) are dependent on experts opinions in order to
select some design constant that have standard intervals. So we
meet a complicated design procedure. To conquer this complicity,

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the AD approach is applied to reduce the effect of designers opinions and the design computation time and to facilitate the design
recovery process.
Additionally, finite element analysis (FEA) is utilized, whose
results closely agree with those issued from optimization outcomes as well as measurements obtained from a manufactured
prototype of the LATM, all of which satisfy the proposal motivations, i.e., optimization method and manufacturing plane.

number of DPs is equal to the number of FRs, the design can be

coupled, decoupled, or uncoupled. If the design matrix is diagonal, the design solution is uncoupled, if the design matrix is triangular, the design solution is decoupled. Otherwise, the design
solution is named as coupled and unacceptable [26]. AD provides
two axioms to conduce the direction of good design. The first
design axiom is known as the independence axiom and the second
axiom is known as the information axiom. They are explained as
following [27]:

AD Methodology

AD is a tool for designing products and processes based on customer needs (CN). This theory is proposed and developed by Suh
in 80s. According to AD every design object can be depicted in
four design domains: the customer, the functional, the physical,
and the process domains as depicted in Fig. 1 [25].
Each domain is characterized by set of information: CN in customer domain, FR, and constraints in functional domain, to meet
the FR, DP are determined in physical domain and process variables (PVs) are defined for manufacturing in process domain.
These domains are linked through several mappings as shown in
Fig. 1. There are three types mapping: (1) mapping between customer domain and functional domain is defined as conceptual
design, (2) mapping between functional domain and physical domain is defined as product design, (3) mapping between physical
domain and process domain is defined as process design. As a
result of these mapping, two design matrices are defined. The first
matrix defines the relations between the FRs and related DPs and
the second matrix depicts the relation between DPs and relative
PVs. The elements of design matrices consist of X and 0 elements such that X symbolizes the existence of relation while
0 symbolizes no relation between domains. In AD, there are
three types of design with respect to the number of FRs and DPs:
(1) if the number of DPs is greater than the number of FRs, the
design is named as redundant. (2) If the number of FRs is greater
than the number of DPs, the design is named as coupled. (3) If the

Axiom 1: The independence axiom: maintain the independence of the FR.

Axiom 2: Information axiom: minimize the information content of the design.

The independence axiom states that the independence of FRs

must always be maintained, where FRs are defined as the minimum set of independent requirements that characterizes the design
goals. With respect to this axiom, the uncoupled and decoupled
designs are acceptable. The information axiom states that among
the design concepts that satisfy the first axiom, the design concept
that has the smallest information content is the best design [1]. Information is defined in terms of the information content, Ii , that is
related in its simplest form to the probability of satisfying the
given FRs. The information content determines that the design
with the highest probability of success is the best design. The information content Ii for a given FRi is defined as [27]
Ii log2

1
pi

(1)

where Pi is the probability of achieving the FRi . In any design situation, the probability of success is given by what designer wishes
to achieve in terms of tolerance (i.e., design range) and what the
system is capable of delivering (i.e., system range).
As shown in Fig. 2, the overlap between the designer-specified
area of the design range and the system capability range area

Fig. 1 The design process as a mapping

Fig. 2 Design, system, and common ranges and probability density function

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of the system range is the region where the acceptable solution

exists. So the information content is equal to [27]


area of the system range
(2)
Ii log2
area of the common range
Where there is incomplete information about system and design
ranges, the fuzzy AD may be introduced. In this case, triangular
fuzzy numbers (TFN) can well define these kinds of expressions.
Because of the differences of expression between crisp and fuzzy
AD, there is a membership function of TFN instead of probability
density function in the crisp case. In order to systemically convert
linguistic terms to their corresponding fuzzy numbers, two numerical approximation systems for tangible and intangible factors
were used by Kulak and Kahraman [28]. So, information content
is equal to [7,27]


TFN of system design
(3)
Ii log2
common area
where the common area is the intersection area of TFN.

the roll-off portions of the curve. In particular, the curves do not

reflect the effects of armature reaction, which depends on both armature current level and magnet strength. The deflection range of
a LATM is generally specified in terms of a so-called excursion
angle. This angle represents the difference between the rotor position that produces maximum torque and the zero-torque point on
the characteristic curve. The constant-torque region of a toroidally
wound LATM that depends on the arc length of each sector of armature winding and the pole arc length is derived as
h0

Definition of the Problem

This work proposes the design procedure and manufacturing

plan of a LATM to meet a specified industrial application. The
configuration of the selected LATM is shown in Fig. 3(a).
In the current research to develop a two-pole LATM for an
industrial control application that requiring a 630 deg rotation
with a peak torque of 2.5 nm, a toroidally wound type solid core
stator with rare-earth pole-tip rotor construction is selected. The
two DC stator windings are connected in series for single-phase excitation by a simple DC circuitry. The rotor carries field magnets and
the stator supports the armature windings. The interaction of these
two magnetic fields produces an electromagnetic torque which
causes an attraction or repulsion force between the rotor and the stator. The magnitude and direction of armature current determines the
magnitude of the electromagnetic torque and rotor movement direction. Manufacturers generally provide a theoretical torque versus
shaft-position curve. Typically, the characteristic curve for LATMs
is represented by the positive lobe of a cosine function; that is,
 p
(4)
T Tp cos h:
2
where h, p, and Tp are, respectively, the angle of rotation, the
number of poles, and the peak torque. The general torque characteristic for toroidally wound motors can be represented by a similar curve, but it may also have a flat portion as shown in
Fig. 3(b).The above equation approximates torque values only for

(5)

where h0 , us , and ur denote the constant-torque range, stator

winding arc angle, and rotor pole arc angle, respectively. The output torque of a LATM is directly proportional to the armature current. Hence, the torque-current characteristic is a straight line with
a slope known as torque sensitivity constant kt .
A comprehensive design uses the MEC model [11]. The model
extracts the geometric parameters relations. The maximum torque
relation in MEC model at position h0 0 is obtained as
Tp

us  ur
2

pkkrs D2i B20 g

l0

(6)

where l0 is free space permeability, g is the length of air-gap, Di

is the inner diameter of stator core, B0 is the air-gap flux density
corresponding to pick torque state, and k and krs are geometric
constants, which represent the ratios of w=Di and ur =us , respectively and w is the axial length of the LATM. The maximum torque is generated in a short time. By considering the maximum
torque instead of continuous torque, LATM size, weight, and cost
can be reduced considerably [11]. The continuous torque is limited by thermal criteria, whereas the maximum torque is usually
limited by magnetic saturation or supply current or voltage capability. Other actuators parameters are calculated in the step by
step design procedure. In the first step ur , us , and p are selected
according to the shape of motor, angular range of constant-torque,
and the required maximum acceleration. The geometric constant k
is usually considered as 0:8  1:6=p for DC machines [11].
Also, the average value of air-gap flux density B0 has a value
between 0.4 and 0.8 T [11]. According to industrial requirements,
the motor axial length w, is limited between 20 mm and 80 mm.
By substituting the given parameters k, B0 , and w in Eq. (6), the
air-gap length is calculated. An important step in LATM design
process is determining the stator and rotor parameters. The selection of an appropriate ferromagnetic material for stator and rotor
cores is very important. The rotor structure is composed of two
radially magnetized PM and one cylindrical ferromagnetic magnet
holder. Proper materials should have low residual magnetism, low
hysteresis loss, and a good saturation value of flux density as well

Fig. 3 (a) The configuration of designed LATM and (b) torque-rotor position characteristic of
a LATM

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as low cost. The geometric parameters of stator and rotor cores

are determined after this step. By considering the continuity of the
magnetic flux from PM to air-gap, the amperes law, and a best
linear curve fitting for demagnetization characteristics (B-H
curve) of PM assuming no saturation, the magnetic path length in
each PM is calculated. Next, electrical and mechanical time constants (TCs) of the LATM are calculated based on the dimensions
and electrical parameters of the motor [11]. Whereas, three parameters k, w, and B0 vary between given upper and lower limits,
for each value of these parameters in their intervals, a LATM may
be designed. The constant parameters of the design should be
selected under a well knowledge of actuator system and experimentations. By defining k, w, B0 and changing these parameters in
the acceptable ranges, a wide variety of the design solutions may
be expected. This leads us to apply a methodology to confine and
optimize the design solutions with higher control over the DPs
with respect to the industrial requirements. So, to determine the
best design solution and extract the manufacturing process plan,
the AD approach has applied as an optimization tool.

In order to select the independent FRs, some requirements

should be considered as constraints. Table 1 shows the selected
constraints in this work.
The relations between FRs and DPs are shown in the design
matrix as Eq. (11). This matrix includes two independents down
triangular sub matrices. According to AD methodology, this matrix is decoupled and does not violate the independence axiom.
So, it is considered as a quite reasonable design. In order to design
LATM, the values of the DPs have to be determined.
#
32 3
3 2"
2
0 0
0
x11
R
CL
76 7
7 6
6
7
6
x
x
0
0
TC
7 6
6
21
22
76 J 7
7
7
6
(11)
"
# 76
7
6V 7 6
76
5 6
4
54 g 5
4 0 0 x33 0
T

The design equations of the first sub matrix are shown in Eqs.
(12) and (13). Considering these equations, CL is the first FR that
should be set by suitable R value in below equation:

Selection of the Best Design Solution of the LATM

A product is designed to meet an overall set of FRs and constraints. In order to design LATM, FRs, and their corresponding
DPs are selected, and the zigzagging between these two domains
is established. The minimum set of independent requirements that
completely characterizes the FRs of the LATM is determined as
follow. The values of the FRs are determined based on limitations
of industrial application of LATM. For example copper losses
(CLs) are the main source of heat generation in the system. The
admissible heat in the system is corresponding to 120 W of CLs.
Furthermore, to track the reference signals, system needs to have
an acceptable speed. The TC of LATM determines this desired
speed. Moreover, industrial application has specific space for
mount an actuator with exact output torque.

FR1
FR2
FR3
FR4

copper losses CL must be 120 W

time constant TC must be 15 ms
volume V must be 400 cm3
peak torque T must be 2:5 nm

CL I 2  R

T2
R
Kt2

(7)

where Kt is torque/current sensitivity coefficient that is equal to

1.11. In accordance with the design relation in Eq. (8), the
moment of inertia (J) is considered as second DP to satisfying the
TC.
TC

RJ
kb  kt

(8)

where induced voltage coefficient kb is equal to kt [11]. Considering the design relation in Eq. (9), in order to satisfy volume (V),
the total air-gap (g) is considered as third DP.
p
V Do 2g  MC2 w 2g  MC
4

(9)

where Do is outer diameter and MC is mechanical clearance (airgap between rotor PMs and winding surface). The design relation
in Eq. (10) is extracted from Eq. (6) with substituting the krs with
the ur =us ratio. In order to satisfy peak torque (T), the air-gap flux
density B0 is considered as fourth DP.
T

pKD2i B20 gur

l 0 uS

051009-4 / Vol. 136, OCTOBER 2014

CL x11  R

(10)

T2
R
Kt2

(12)

With respect to the values of CL and T of the actuator as two

FRs, the terminal resistance (R) is equal to 29.64 X. By having
the value of R, in order to adjust the TC value, it is sufficient to
determine the moment of inertia (J) in below equation:
TC x21  R x22  J

RJ
kb  kt

(13)

Considering the kb and kt coefficients, J is equal to

6:23  104 kgm2 . In accordance with the first row of the second
sub matrix, and the design relationship (9), the relation of the volume (V), and total air-gap (g) are as follows:
V x33  g

Considering the design relation in Eq. (7), in order to satisfy

CLs, the terminal resistance (R) is considered as first DP.

B0

x44

x43

p
Do 2g  MC2 w 2g  MC
4

(14)

In order to select the LATM volume as the third FR, the total
air-gap (g) should be determined. Considering the outer diameter
Do and MC, the value of g is equal to 4:325 mm. In addition,
the relation of air-gap flux density B0 , and peak torque (T) are
depicted as
T x43  g x44  B0

pKD2i B20 gur

l0 uS

(15)

In order to select peak torque, it is required to determine the

value of B0 . With respect to the values of p, k, Di , and krs as constraints, the value of B0 is equal to 0.43 T. In traditional design of
LATM, the designer should select a value for B0 from a specific
interval based on experience. However, the AD methodology
eliminates the trial and error in selection of B0 and gives a specific
value for it.

Table 1

The industrial requirements of the LATM

Industrial requirements
Number of poles
Outer diameter (mm)
Axial length (mm)
MC (mm)
k (axial length/inner diameter)
rotor pole arc angle
stator winding arc angle

Value
2
100
40
1.5
0.55
120 deg
180 deg

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Fig. 4
Table 2

As regards to independence axiom, this matrix is diagonal and

shows an uncoupled design. There are several PVs alternatives
that satisfy DPs. For example, in order to satisfy terminal resistance (R), two types of wire may be selected. They are single layer
and double layer insulation wires. A most useful permanent magnet is selected for the rotor according to their properties. For high
torque capability and energy product, NdFeB35 is chosen. The
alternatives for WM, CM, and PT are illustrated in Fig. 4.
In order to choose the best alternative for each PV, both cost
and thermal performance criteria are considered. The information
axiom is used to select the optimum manufacturing process plan
based on these criteria as follow.

The alternatives of each PV

5 Selection of the Best Manufacturing

Process Plan of the LATM

All the manufacturing process plans

Number of manufacturing
process plan
1
2
3
4
5
6
7
8
9
10
11
12

WMl

PT

CM

Single layer
Single layer
Single layer
Single layer
Single layer
Single layer
Double layer
Double layer
Double layer
Double layer
Double layer
Double layer

Wire cut
Milling
Wire cut
Milling
Wire cut
Milling
Wire cut
Milling
Wire cut
Milling
Wire cut
Milling

Steel SA1010
Steel SA1010
Steel SA1020
Steel SA1020
Permendor
Permendor
Steel SA1010
Steel SA1010
Steel SA1020
Steel SA1020
Permendor
Permendor

So as to manufacture LATM, it is necessary to define the PVs

to satisfy each DP. In this work, wire material (WM), core material (CM), production technology (PT), and permanent magnet
material are considered as PVs to specify the terminal resistance,
moment of inertia, total air-gap and air-gap flux density, respectively. The relations between DPs and PVs are shown in design
matrix as
2

6
6J
6
6g
4

x11

7 6
7 6 0 x22 0
76
7 6 0 0 x
5 4
33

B0

WM

76
0 76 CM
76
6
07
54 PT

7
7
7
7
5

x44

0 0 0

32

(16)

PMM

There are twelve manufacturing process plans of LATM where

selecting the PVs alternatives. For example, first plan consist of a
single layer wire, steel SA1010 as stator and rotor cores and wirecut technology to manufacture the stator and rotor. Therefore,
designers are faced to the problem of selecting the best manufacturing process plan among 12 alternatives. All manufacturing process plans are depicted in Table 2. Information axiom may be
used as a decision making tool to help in the process planners. In
order to select the best alternative, the four steps are implemented
as follows.
5.1 Evaluation of the Alternative of PVs Based on Cost
and Thermal Performance Criteria. In order to evaluate the
PVs alternatives, both cost and thermal performance criteria are
considered. In this study, the symbol A is considered as the unit
of cost. Thermal performances of alternatives are expressed by
linguistic terms. The following numerical approximations system
is proposed to convert linguistic terms to their corresponding
fuzzy numbers as shown in Fig. 5. This figure shows that the TFN
0; 0; 15 is very low, 10; 20; 30 is low, 25; 40; 55 is medium,
45; 60; 75 is high, and 65; 100; 100 is very high. Based on
experts opinion, the evaluation of alternatives for WM, CM, and
PT are expressed with respect to cost and thermal performance as
shown in Table 3. For example, to calculate the cost of single
layer wire, the weight of whole required length is multiplied by
the price per weight. Moreover, experts subjectively evaluate single and double layer wires with respect to thermal performance
with the linguistic terms Medium and High, respectively.

Fig. 5 The numerical approximation system for thermal performance criterion

Table 3 The evaluation of the alternatives for WM, CM, and PT

Evaluation

Single layer

Double layer

Steel SA1010

Steel SA1020

Permendor

Wire cut

Milling

Cost (per unit A)

Thermal performance

[29.0, 72.5]
Medium

[58.0,101.5]
High

[7.1,14.2]
Low

[14, 21]
High

[21.9, 29.2]
Very high

[150, 250]
Medium

[100, 120]
High

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Fig. 6 Design, system and common ranges of cost for first manufacturing process plan

Table 4 System range data and information content of cost

Number of manufacturing
process plan

System
range

Design
range

[186.1,336.7] 120; 150

[136.1,206.7]
[193.0,343.5]
[143.0,213.5]
[200.9,351.7]
[150.9,221.7]
[215.1,365.7]
[165.1,235.7]
[222.0,372.5]
[172.0,242.5]
[229.9,380.7]
[179.9,250.7]

1
2
3
4
5
6
7
8
9
10
11
12

1.2368
0
1.4007
0
1.6188
0
2.1094
0
2.4263
0
2.9074
0.0143

5.2 Calculation of the Information Content of Cost for

Each Manufacturing Process Plan. The total cost of each manufacturing process plan is totality of constitutive alternatives cost.
For example, the total cost of first plan is totality of the required
single layer wire cost and iron core cost and wire cut manufacturing cost. This value determines the system range of each manufacturing process plan based on the cost criterion. The range
120A; 250A is suggested as the cost design range by designers.
Uniform probability density functions have used for the cost,
since the design and system ranges have been equally probable.
The design, system, and common ranges for the first manufacturing process plan based on the cost are illustrated in Fig. 6.

IC log2

Information content
of cost criterion

Design range based on cost is equal to 120A; 250A.

System range for first manufacturing process plan is equal to
186:1A; 336:7A.
Common range that is the overlap between system and design
ranges is equal to 186:1A; 250A.




system range
336:7  186:1
log2
1:236
common range
250  186:1
(17)

The system ranges and the information content of the cost for
all the manufacturing process plans are depicted in Table 4.
5.3 Calculation of the Information Content of Thermal
Performance for the Alternatives. Unlike the cost, the thermal
performance is a qualitative criterion. So, the thermal performances of the manufacturing process plans are not equal to the aggregation of the values of this criterion for all the constitutive
alternatives. Therefore, the information content for all the PVs
alternatives must be calculated. For example, the information content of thermal performance for single layer wire is illustrated as
Fig. 7.

Design range based on thermal performance for the single

layer wire is equal to 50; 62:5; 75.
System range for the single layer wire is equal to 25; 40; 55.
Common area that is intersection area of TFNs is equal to
0.454.




TFN of system design
15
log2
5:0457
It log2
common area
0:454
(18)
where It is the information content of thermal performance
for the single layer wire. The system and design ranges and
the information content of thermal performance for all the
alternatives are depicted in Table 5.

In order to obtain the information content of thermal performance for the manufacturing process plans, the values of information content of this criterion for all the constitutive alternatives

Fig. 7 Design, system ranges and common area of thermal performance criterion for single
layer wire

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Table 5 System and design range data and information content of thermal performance for all the alternatives
PV

WMl

The alternatives
of PVs

System
range

Design
range

Information content of
thermal performance

Single layer
Double layer

[25,40,55] [50,62.5,75]
[45,60,75] [50,62.5,75]

5.0457
0.4005

PT

Wire cut
Milling

[25,40,55] [45,52.5,65]
[45,60,75] [45,52.5,65]

1.8754
1.0445

CM

Steel SA1010
Steel SA1020
Permendor

[10,20,30] [25,47.5,70]
[45,60,75] [25,47.5,70]
[65,100,100] [25,47.5,70]

4.7082
0.5859
5.3334

Table 6
Number of
manufacturing
process plan
1
2
3
4
5
6
7
8
9
10
11
12

The total information contents

Information
content of
thermal performance

Information
content
of cost

Total
information
content

11.6293
10.7984
7.5070
6.6761
12.2545
11.4236
6.9841
6.1532
2.8618
2.0309
7.6093
6.7784

1.2368
0
1.4007
0
1.6188
0
2.1094
0
2.4263
0
2.9074
0.0143

12.8661
10.7984
8.9077
6.6761
13.8733
11.4236
9.0935
6.1532
5.2881
2.0309
10.5167
6.7927

should be gathered. For example, the information content of thermal performance for the first manufacturing process plan is totality of the information content of this criterion for the single layer
wire, the iron core and the wire cut technology. The information
content of thermal performance for each manufacturing process
plan is illustrated as column 2 in Table 6.
5.4 Calculation of the Total Information Content and
Selection of the Best Manufacturing Process Plan. In order to
calculate the total information content for each manufacturing
process plan, the values of information content with respect to
both cost and thermal performance criteria for each plan are gathered. The results are shown in Table 6.The manufacturing process

Fig. 9 Pictures of the proposed LATM parts: (a) rotor, (b) armature windings, (c) assembled LAT, and (d) experimental setup

plan No. 10 has the smallest value of total information content.

This plan consists of a double layer wire, steal SA1020 as stator
and rotor cores and milling technology to manufacture the stator
and rotor. According to the information axiom, this plan is
selected as the best manufacturing process plan based on the cost
and thermal performance criteria.

FEA and Experimental Results

So as to compare the optimization outcomes of the studied

LATM, FEA is performed. Figure 8 shows the magnetic flux density distributions within the designed LATM without and with stator excitation, wherein it is seen that the ferromagnetic parts
magnetically operate at 1.5 T which guarantees that the CMs are
not saturated, all of which emanates from the presented design
considerations for materials and geometrical parameters.
Based on the design data given in Table 1, a prototype LATM
has been manufactured as illustrated in Fig. 9. It is worth noting
that rotor components are glued by an epoxy adhesive, an adhesive material whose main benefits are strength and environmental
resistance. The torque-angle characteristic of the machine is
extracted through the experimental test setup shown in Fig. 9(d).
The measured torque-angle characteristic of the LATM along
with the FEA results was already depicted in Fig. 10(a). It is
observed that the measured data agrees well with those obtained
from FEA. The experimental position response of the prototype
motor that correlates well with the simulation result of the LATM

Fig. 8 FEA of designed LATM (a) without stator excitation and (b) with stator excitation

Journal of Manufacturing Science and Engineering

OCTOBER 2014, Vol. 136 / 051009-7

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Fig. 10 (a) Torque-angle characteristic and (b) position responses of the LATM to a step input voltage obtained from finite element simulations and test

as given in Fig. 10(b). It is seen that the rotor rotates from 0 to

90 deg 250 ms which illustrates a satisfactory transient response.

Conclusion

In this work, a novel design process based on the AD theory for

a LATM is developed. Having used the independence axiom, the
trial and error procedure in determining the main DPs are eliminated and the values of the DPs are calculated directly. This methodology explicitly extracts the design procedure from the first to
the last stages. Also, the optimum manufacturing process plan
with respect to both cost and thermal performance is selected
among several alternatives by the information axiom. With
respect to this axiom, not only the most cost-effective manufacturing process plan, but also the most efficient performance criterion
for the LATM is determined. Finally, finite element method is
employed to validate the results obtained by optimizations as well
as experimental outcomes extracted from the manufactured prototype of the device. All taken together satisfy the proposed
approach, i.e., optimization method and manufacturing process.
The results of the current study were promising where using AD
methodology in an industrial case. However to get a precise
results, the application of zigzag method on breaking down the
FR, DP, and PVs in the lower levels is suggested for further
study.

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