Loss-aware multi-objective optimization framework for efficiency and cost improvement in spoke-type permanent magnet synchronous motor

This paper presents a systematic multi-objective optimization framework for improving the efficiency and reducing the production cost of a spoke-type permanent magnet synchronous motor (PMSM). The proposed approach employed a design of experiments (DOE) methodology combined with analytical and experimental efficiency evaluations to identify optimal trade-offs between performance and material cost. This paper investigated the effects of key design parameters including stack length, winding turns, wire diameter and axial stator-rotor proportion on the overall motor performance. Statistical analysis based on regression and design of experiments was performed to establish predictive models of efficiency and cost under multiple operating conditions. The results confirmed that the proposed DOE-based optimization was able to effectively improve efficiency while maintaining material cost constraints, providing practical guidelines for high-performance and cost-effective PMSM designs in fan and HVAC applications.