Novel hybrid design methodology for a surface permanent magnet synchronous motor

The present paper introduces a novel hybrid design methodology for surface permanent magnet synchronous machines. The method combines analytical and optimal design with finite element method (FEM) analysis, in order to obtain the best prototype that meets specific requirements. High efficiency and minimum cost is aimed through analytical and optimal design, while high torque capability and low cogging torque is then achieved by FEM analysis and several penalty coefficients that are introduced. A Matlab program is developed for this purpose. It implements the analytical and optimal design, calls the FEM program, draws the motor geometry, makes the finite element analysis, verifies the prototype´s characteristics and if the cogging torque is too high or the total torque obtained is not satisfactory, the penalty coefficients introduced in the design code start again the whole design process. The repetitions are made until the “torque conditions” are satisfied or a maximum number of iterations is reached. The prototype is designed for the automotive air conditioning compressor drive application.