Optimal design and finite element analysis of a high speed, axial-flux permanent magnet synchronous motor

Permanent magnet synchronous motors (PMSMs) have been considered in many high-speed applications. Gaining the maximum torque density with minimum losses is the goal of design in such applications. This paper presents the design and optimization of an axial-flux permanent magnet motor with 300 Watt rated at 60,000 rpm. Based on analytical relations of motor design, the specifications and dimensions of motor are determined. Due to special application of designed motor that needs to demanded torque with minimum current and copper losses, dimensions and design specifications of motor is optimized via genetic algorithm. Optimization algorithm determines the optimum value of air gap, permanent magnet flux density, current density and turns number of stator windings. To demonstrate of analytical design and optimization results, using 3-D model of motor in Maxwell software, a finite element analysis is carried out. The simulation results show the significant reduction in RMS current and copper loss at rated torque. There is a good agreement between analytical design and FEM analysis results and it confirms the effectiveness of presented optimization algorithm.