Design, Analysis, and Prototyping of a Formula SAE Application Flux-Switching Permanent Magnet Motor

This paper investigates the design, analysis, and prototyping of a Flux-Switching Permanent Magnet (FSPM) motor for Formula SAE electric vehicle applications. The stringent competition requirements demand traction motors with high torque and power density, and reliable operation at elevated speeds. An analytical model based on air-gap permeance and magnetomotive force distributions is developed to provide an effective preliminary design tool and to reduce computational effort. The proposed model is used to define the main geometrical parameters of a 12-slot, 10-rotor-tooth FSPM machine, which is subsequently validated through finite element analysis. Analytical and numerical results are compared in terms of air-gap flux density, flux linkage, and torque capability, showing good agreement. Manufacturing-driven design choices, including optimized magnet slot geometry, laminated permanent magnets for eddy-current loss mitigation, and a mechanically robust lightweight rotor, are introduced to ensure high-speed operability and assembly reliability.