Multiphysics-Constrained Optimization of an Axial-Flux Consequent-Pole Motor for Electronics Cooling Systems

Abstract Electronics cooling systems depend on compact motor-driven pumps to maintain thermal stability in high-power electronic applications. In such systems, improving motor torque density alone is insufficient, as electromagnetic enhancement must be achieved without compromising thermal safety or mechanical integrity under continuous thermal loading. This study proposes a multiphysics-constrained optimal design procedure for a 1.5 kW axial-flux consequent-pole motor (AFCP) intended for electronics cooling systems. Unlike conventional electromagnetic-only optimization approaches, the proposed procedure integrates topology selection, surrogate-assisted optimization, and multiphysics verification in a systematic manner. Four consequent-pole (CP) configurations were comparatively analyzed to identify a baseline topology exhibiting favorable torque characteristics and magnetic loading distribution. A regression-based surrogate model combined with a genetic algorithm was employed to optimize ten geometric design variables while enforcing explicit constraints on torque ripple, cogging torque, and electromagnetic operating limits. The optimized design was validated through three-dimensional finite element analysis (3D FEA) and subsequently assessed for structural and thermal feasibility under rated operating conditions. The optimized motor achieved a 5.6% increase in average torque, a 24.89% reduction in torque ripple, and a 29.73% decrease in cogging torque while reducing magnet volume by 21.16%. Multiphysics verification confirmed that these improvements were achieved without exceeding structural or thermal limits. These results demonstrate that the proposed optimal design procedure enables simultaneous enhancement of electromagnetic performance and thermal robustness for motor-driven electronics cooling applications.