Design Optimization of Dual-outlet Blower Motor Using Finite Element and Taguchi Methods for Air-conditioning Applications

In this study, we present the design and optimization of a compact dual-outlet blower motor developed for commercial vehicle air-conditioning systems.The proposed motor was engineered to meet stringent performance requirements across both low-and high-speed operating ranges.The initial motor geometry was modeled and analyzed using Altair FluxMotor, after which Altair Flux2D was employed for mesh generation, circuit configuration, and detailed electromagnetic performance evaluation, including torque ripple, back electromotive force (back-EMF), efficiency, and line-to-line voltage.A comparative assessment of multiple slot/pole configurations identified the 8-pole/12-slot topology as the most suitable design.Sensitivity analysis revealed that slot opening width, air gap, magnet thickness, magnet arc angle, number of turns, and wire diameter are the dominant parameters affecting overall motor behavior.To achieve systematic and efficient optimization, the Taguchi method was applied.Simulation results showed that, at an input current of 1.35 A and a speed of 2678.5 rpm, the motor efficiency improved from 67 to 82%.Under a constant line-to-line voltage of 21 V, the speed increased from 2678 to 3178 rpm, efficiency rose from 67 to 74.1%, and torque ripple was markedly reduced from 114 to 22.2%.Furthermore, the fabricated prototype and experimental validation confirmed close agreement with the simulation outcomes.These results demonstrated the effectiveness of the proposed optimization methodology and highlighted its applicability to developing compact, high-efficiency blower motors for modern vehicle air-conditioning systems.