Manufacturing-Based Design Methodology of Permanent Magnet Machines Considering Practical Slot-Filling Factor

The slot-filling factor is the paramount parameter that significantly affects the performance of electric machines. Nevertheless, an accurate derivation of this parameter, reflecting the manufacturing environment, has posed a significant challenge in previous research. To address this issue, this article presents a novel method that utilizes interstices to calculate the slot-filling factor. Integrating the noniterative approach and employing differential evolution (DE), the proposed methodology incorporates winding manufacturing capabilities into the design scheme of electric machines. Consequently, the design optimizations for permanent magnet (PM) machines are progressed using the proposed method. By comparing multifarious optimization results, this article demonstrates the overestimating tendency inherent in the existing approach, highlighting the substantial impact that the practical slot-filling factor can have. Finally, the validity of the proposed analytical model is verified by the finite element (FE) and experimental results.