Multi-Electromagnetic Performance Optimization of Double-Layer Interior Permanent Magnet Synchronous Machine

Permanent magnet (PM) machines garner significant attention due to their high-power density and high efficiency. As research progresses, high-end motor applications are placing higher and more comprehensive performance demands on PM machines, driving the need for multifaceted and synergistic motor design optimization. In response to this demand, this article proposes a multi-objective optimization design process aimed at improving the overall electromagnetic performance of PM machines. The objectives include enhancing torque density, suppressing torque ripple, and reducing vibration and noise. The optimization process utilizes a meta-model fitted to the numerical model solved by the finite element method, leading to a substantial acceleration of the overall optimization process. Furthermore, an optimization approach is employed to optimize several key structural parameters of a double layer interior PM machine using an evolutionary algorithm. The resulting optimized motor is fabricated and tested, and both numerical simulations and experiments validate that the optimized motor exhibits enhanced torque, low torque ripple, and avoids resonance vibration noise near the rated speed. This comprehensive validation confirms the effectiveness of the structural design and the optimization process.