This paper presents an optimum design of a lightweight vehicle levitation electromagnet, which also provides a passive guide force in a magnetic levitation system for contactless delivery applications. The split alignment of C-shaped electromagnets about C-shaped rails has a bad effect on the lateral deviation force, therefore, no-split positioning of electromagnets is better for lateral performance. This is verified by simulations and experiments. This paper presents a statistically optimized design with a high number of the design variables to reduce the weight of the electromagnet under the constraint of normal force using response surface methodology (RSM) and the kriging interpolation method. 2D and 3D magnetostatic analysis of the electromagnet are performed using ANSYS. The most effective design variables are extracted by a Pareto chart. The most desirable set is determined and the influence of each design variable on the objective function can be obtained. The generalized reduced gradient (GRG) algorithm is adopted in the kriging model. This paper's procedure is validated by a comparison between experimental and calculation results, which shows that the predicted performance of the electromagnet designed by RSM is in good agreement with the simulation results.
Keywords: design of experiments (DOE); electromagnet; kriging interpolation method; levitation control; optimum design; response surface methodology (RSM).