Design Optimization of Permanent Magnet Synchronous Motors: An Analytical Review and Case Study

İngilizce (OpenAlex)

Permanent Magnet Synchronous Motors (PMSMs) are widely used in industrial and electric vehicle applications for their high efficiency, compact size, and precise controllability. However, cogging torque remains a key issue, causing vibration, noise, and performance loss, especially at variable speeds. This study presents a Finite Element Analysis (FEA)-based parametric optimization approach to improve the magnetic and structural performance of a 20-kW, 138-V, 6-pole PMSM. Instead of heuristic algorithms, the method refines key geometric parameters such as magnet thickness, pole embrace, and pole offset that strongly affect flux distribution, torque, and vibration. Using ANSYS Maxwell, simulations analyze their effects on efficiency, air-gap flux density, and cogging torque. Results indicate a decrease in cogging torque from 7.56 Nm to 4.74 Nm and an approximate 15% enhancement in efficiency, leading to improved torque smoothness and more uniform magnetic flux distribution. The study highlights the importance of precise geometric optimization for higher performance and lower noise.