Evaluation of Multi-Tooth Stator-Rotor Modifications for Torque Enhancement in 6/4 Switched Reluctance Motors

The switched reluctance motor (SRM) is a promising candidate for high-torque electric drive applications due to its simple construction, high reliability, and cost-effectiveness. However, conventional SRM designs are limited by torque ripples, acoustic noise, and magnetic flux saturation, which constrain their performance. This study introduces a Teeth-on-Tooth (TeOnTo) configuration, in which each stator and rotor pole is subdivided into multiple smaller teeth to concentrate magnetic flux and shorten the flux path. A systematic finite element analysis (FEA) using Siemens Simcenter MAGNET was carried out on 36 stator–rotor combinations, of which 19 representative models are reported in detail to investigate the influence of tooth count and slot depth on torque, acceleration, efficiency, and weight reduction. Results show that moderate tooth segmentation yields substantial improvements in torque per unit volume, with the 18/16 configuration achieving a 203% peak torque increase over the baseline 6/4 SRM and over 1 kg weight savings. Excessive segmentation approaches material saturation, resulting in diminishing or negative performance gains. While the findings are currently based on simulation, the observed trends are expected to generalize to other SRM topologies with similar materials and operating conditions. The proposed TeOnTo approach offers a practical and scalable pathway to improve SRM torque capability, acceleration, and efficiency while reducing material usage, making it attractive for high-performance electric vehicle and industrial drive systems.