Torque Ripple Reduction and Efficiency Enhancement of Flared-Type Consequent-Pole Motors via Asymmetric Air-Gap and Structural Optimization

The consequent-pole interior permanent-magnet (CPM) motor is a promising alternative for minimizing rare-earth magnet usage while supporting high-speed operation. However, rotor flux asymmetry often leads to distorted back-electromotive force waveforms and increased torque ripple. This study investigated a flared-type CPM motor that employs ferrite magnets arranged in a flared configuration to enhance flux concentration within a compact rotor. To address waveform distortion, structural modifications such as bridge removal and an asymmetric air-gap design were implemented. Three rotor parameters—polar angle, asymmetric air-gap length, and rotor opening length—were optimized using Latin hypercube sampling combined with an evolutionary algorithm. Finite element method analyses conducted under no-load and rated-load conditions showed that the optimized model achieved a 77.8% reduction in torque ripple, a 43.4% decrease in cogging torque, and a 0.5% improvement in efficiency compared with the basic model. Stress analyses were performed to examine the structural bonding strength and rotor deformation of the optimized model under high-speed operation. The results revealed a 5.5× safety margin at four times the rated speed. The proposed approach offers a cost-effective and sustainable alternative to rare-earth magnet machines for high-efficiency household appliances, where vibration reduction, cost stability, and energy efficiency are critical.