Multi-physics and multi-objective optimization of a high speed PMSM for high performance applications

High-speed permanent magnet synchronous machine (PMSM) can provide high power density and high efficiency, which is often highly desirable in high performance applications. A multi-physics optimization program based on the multi-objective genetic algorithm was developed in this paper, to achieve a tradeoff solution between the electromagnetic, mechanical, and thermal aspects. First, the parametric electromagnetic model was modeled based on the finite-element method, and then a thermal network model and an analytical mechanical model to determine the thickness of the magnet and the sleeve were developed and merged within a design cycle of the machine, in an effort to attain the target performances of 20 kW/kg at 20 000 r/min for a 2 MW PMSM. Optimization results indicated that a final design with eight poles and 48 slots could obtain a comprehensive performance between power density and efficiency, and the performance satisfied all the requirements.