Automated Metamodel-Based Framework for the Design Optimization of Externally Excited Synchronous Machines

Automated simulation-driven design is an approach that leverages computational simulations and automation to accelerate product development and optimize designs. While the degree of automation varies depending on the application and methods used, the resource-intensive nature of computational simulations has driven ongoing research into replacing them with so-called surrogate models. This paper presents a fully automated framework for the design optimization of Externally Excited Synchronous Machines (EESMs). The proposed workflow incorporates a surrogate model to predict the key performance indicators (KPIs), minimize the computational cost and reduce reliance on expensive FE resources. A multi-objective optimization algorithm is applied to explore optimal design that can best meet the optimization objectives, such as minimizing torque ripple and total motor losses. The proposed method is validated through finite element analysis (FEA), demonstrating improved electromagnetic performance and efficiency over the baseline design.