Structural Optimization Design and Analysis of Interior Permanent Magnet Synchronous Motor with Low Iron Loss Based on the Adhesive Lamination Process

The interior permanent magnet synchronous motors (IPMSMs) are extensively applied in the field of new energy vehicles due to their high-power density and excellent performance control. However, the iron loss has a significant impact on their performance. This study conducts an optimization analysis on the processing technology of silicon steel sheets and motor structure, targeting the reduction of iron loss and the improvement of the motor’s integrated efficiency. Firstly, the influences of two iron core processing technologies on iron loss, namely gluing and welding, are compared. Through experimental tests, it is found that the iron loss density of the gluing process is lower than that of the welding process, and as the magnetic flux density increases, the difference between the two is expanding. Therefore, the iron loss test data from the adhesive process are employed to develop a variable-coefficient iron loss model, enabling precise calculation of the motor’s iron loss. On this basis, aiming at the problem of excessive iron loss of the motor, a novel topological structure of the stator and rotor is proposed. With the optimization goal of reducing the motor iron loss and taking the connection port of the air magnetic isolation slot and the gap of the stator module as the optimization variables, the optimized design of the IPMSM with low iron loss is achieved based on the Taguchi method. After optimization, the stator iron loss decreases by 13.60%, the rotor iron loss decreases by 20.14%, and the total iron loss is reduced by 15.34%. The optimization scheme takes into account both the electromagnetic performance and the process feasibility, it offers technical backing for the high-efficiency operation of new energy vehicle drive motors.