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A novel PID controller design method is proposed in the paper for PMSM Servo system using particle swarm optimization (PSO). The detailed procedures for optimal PID controller design are summarized in terms of the principle of particle swarm optimization. In order to overall optimize the performance of the system step response, a new evaluation strategy (fuzzy hamming distance) is introduced for evaluating the performance. Comparisons between the results obtained by GA method and those by PSO method are made. The simulation and experimental results show that the PSO method can locate the optimal or near optimal parameter space and achieve a higher quality solution than the GA method. Hence it affords a new and better optimization tool for optimal PID controller design in complex and coupled systems.