A Comprehensive Performance Assessment of the Combined URSA and Dedicated Notching Methods in Flux-Switching Machines

This study focuses on improving the electromagnetic performance of flux-switching permanent magnet (FSPM) machines as a high-efficiency alternative aligned with the “green industry” concept. FSPM machines offer high torque density and mechanical robustness due to their stator-mounted magnet design; however, they suffer from cogging torque and torque ripple caused by magnet–stator tooth interactions. Three structural optimization methods were applied to a 12-slot, 10-pole reference FSPM machine: rotor notching, unequal rotor slot arc (URSA), and a hybrid approach combining both techniques. Eight models (D0–D7) were analyzed using genetic algorithms and the two-dimensional finite element method (FEM). Results demonstrate significant performance improvements while maintaining power density. The D1 design reduced torque ripple from 9.2% to 1.59%, achieving approximately a sixfold improvement. The D3 design yielded the lowest cogging torque at 0.4 Nm. Hybrid configurations (D5–D7) exhibited consistent performance with high back-EMF amplitude and uniform torque distribution. Physical manufacturability was validated through laser-cut prototype production of the optimized models. These findings highlight the strategic potential of FSPM machines for electric vehicle and industrial automation applications requiring precise positioning and high efficiency.