MOPSO-Based Design Optimization for Armature Coils in High-Propulsive-Force Electrodynamic Vibrators

Directly coupled electrodynamic vibrators are widely used in vibration testing due to their ability to generate large propulsive forces. However, increasing the propulsive force typically requires higher driving currents, which leads to significant electrical heat generation and thermal management challenges in the armature coil. To address this issue, this study proposes a multi-objective parameter optimization framework for the design of armature coils in high-propulsive-force electrodynamic vibration tables. Two optimization objectives are formulated based on electromagnetic and thermal considerations: minimization of electrical heat generation in the armature coil; and improvement in cooling capability, characterized by the ratio between the cooling water channel area and the conductive cross-sectional area. The key geometric parameters of the coil, including winding configuration and cross-sectional dimensions, are treated as design variables. The resulting multi-objective optimization problem is solved using a multi-objective particle swarm optimization (MOPSO) algorithm to obtain a set of Pareto-optimal solutions that balance the two competing thermal objectives. The present work focuses on the pre-design-stage optimization of the armature coil after the rated propulsive force and geometric envelope of the vibrator have been specified. A representative high-propulsive-force electrodynamic vibrator is analyzed as a case study. Finite element thermal simulations show that the selected Pareto-optimal design reduces the peak armature-coil temperature by approximately 9.7–36.6% compared with the other investigated coil configurations under the same propulsive force condition. The proposed method provides an efficient approach for the thermally constrained parameter design of high-power electrodynamic vibrator armature coils.