Finite element analysis driven optimization of an electrodynamic levitation system with permanent magnet Halbach arrays

This study presents a finite element analysis (FEA)-driven optimization for the design of an electrodynamic levitation (EDL) system incorporating permanent magnet Halbach arrays (PM-HAs). The primary objective is to maximize the net force difference between lift (Fy) and drag (Fx) forces under realistic physical and manufacturing constraints. The nonlinear electromagnetic behavior of the EDL system is modeled using high-fidelity FEA, capturing the complex interaction between the PM-HA and a conductive plate. At each iteration of the population-based optimization algorithm, full magnetoquasistatic simulations are performed to ensure a physically accurate evaluation of key performance metrics. A comprehensive parametric study involving 256 distinct PM-HA configurations reveals a non-monotonic relationship between the number of magnets and levitation performance, highlighting the critical role of magnetic field distribution. Configurations with 9 to 11 magnets achieve the highest net levitation force. The optimization results indicate that the optimal configuration includes four horizontally aligned permanent magnets (PMs) with a width of 74.00 mm and three vertically aligned PMs with a width of 74.67 mm, along with a 7 mm thick conductive plate having a conductivity of 5 ×107 S/m. This design delivers a maximum lift force of 3550 N and a minimum drag force of 279 N at 100 m/s. The findings demonstrate that effective EDL system design requires a carefully arranged magnet configuration rather than a simple maximization of magnet count or size. The proposed FEA-guided framework offers a robust and scalable methodology for the optimization of high-performance Maglev systems.