Efficiency optimization of spoke-shaped interior permanent magnet synchronous motor using FEA integrated Rao-algorithms and its thermal analysis

Abstract This paper focuses on the design of a spoke-shaped interior permanent magnet synchronous motor (S-IPMSM) with its efficiency and cost optimizations, which are suitable for low-power applications. The motor rating considered is 0.55 kW with an applied voltage of 220 V. Concerning constant output power, speed, phase current, and voltage excitation, this study focuses on improving electromagnetic torque by optimizing the design parameters of S-IPMSM. This analysis has been processed by using meta-heuristic Rao’s optimization algorithms (Rao-1, Rao-2, and Rao-3) and finite element method (FEM). Optimization of design parameters of stator and rotor parts of IPMSM has been achieved in MATLAB. Finite element (FE) models developed in the ANSYS platform have been used to validate the optimization method results and compared to ensure the accuracy of the algorithms. The differences among optimized models from the Rao series are considered for FE analysis, and its results are compared. Parameters like efficiency, airgap magnetic field density (B air ), electromagnetic torque (T em ), and magnetic flux density (B) under steady-state and transient conditions are observed and improved. Including these, the cost analysis of materials used for motor design is also analyzed, and comparative results are reported. As a result of FE models incorporating all parameters, improved motor performance has been observed. To better understand, the performance of three cases with different stator slot numbers (18, 24, 30) are considered in the study. It is observed that the models of Rao-1, Rao-2, and Rao-3 are competitive with each other. Additionally, a thermal analysis of IPMSM is performed to show the effective temperature distribution within the motor.