Rotor Flux Barrier Design for Torque Improvement in Synchronous Reluctance Motor

Motivated by the increasing demand for sustainable electric machines, reducing reliance on rare earth materials is essential. These materials pose significant environmental challenges, including depletion and pollution. Synchronous reluctance motors present a viable alternative to permanent magnet motors, as rare earth materials are not required. They also offer robust performance. This paper aims to optimize the design of rotor flux barriers in a synchronous reluctance motor. The synchronous reluctance motor under test is obtained by replacing the cage rotor of an induction machine with the designed rotor. The focus is based on minimizing torque ripple while enhancing mean torque. A comprehensive design workflow is implemented, combining analytical tools, finite element simulations, sensitivity analysis, and mechanical validation. Twelve geometrical parameters are systematically varied to evaluate their impact on motor performance. The results yield a major reduction in torque ripple from 41% to 17.5%, as well as a 13% increase in torque capability compared to the initial design. These findings demonstrate significant improvements in motor performance. The results enhance the effectiveness of optimizing synchronous reluctance motors to meet sustainability goals in various industrial applications.