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<p>In this paper, a three-layer optimization method for flat-wire permanent magnet synchronous motors (PMSMs) is proposed considering the characteristic current variation. First, the relationship between the characteristic current and the flat-wire layer number is studied, which shows the influence of the flat-wire layer number on the speed regulation capability of PMSMs. Then, a double-layer V-shaped PMSM is then taken as an example and subjected to optimization using the proposed three-layer method. In layer-1, the speed regulation capability with different flat-wire layers is analyzed based on the theoretical investigation of the characteristic current. An evaluation function is established considering the speed regulation capability and AC copper loss to obtain the optimal flat-wire layer. In layer-2, the dimension optimization is carried out on the PMSM with optimization objectives of maximum torque and minimum torque ripple. Several optimal motor cases are selected on the obtained Pareto frontier. In layer-3, the characteristic current analysis is carried out on selected motor cases for optimizing the speed regulation capability. The final optimized PMSM is compared with the original one, which shows superiorities in terms of torque, speed regulation range, and efficiency.</p>

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Hierarchical optimization of flat-wire winding permanent magnet motors considering characteristic current variation

  • 期刊论文

  • 发表日期：

    2026年4月27日

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  • Han Chen,
  • Yi Du,
  • Zhuofan He

摘要

In this paper, a three-layer optimization method for flat-wire permanent magnet synchronous motors (PMSMs) is proposed considering the characteristic current variation. First, the relationship between the characteristic current and the flat-wire layer number is studied, which shows the influence of the flat-wire layer number on the speed regulation capability of PMSMs. Then, a double-layer V-shaped PMSM is then taken as an example and subjected to optimization using the proposed three-layer method. In layer-1, the speed regulation capability with different flat-wire layers is analyzed based on the theoretical investigation of the characteristic current. An evaluation function is established considering the speed regulation capability and AC copper loss to obtain the optimal flat-wire layer. In layer-2, the dimension optimization is carried out on the PMSM with optimization objectives of maximum torque and minimum torque ripple. Several optimal motor cases are selected on the obtained Pareto frontier. In layer-3, the characteristic current analysis is carried out on selected motor cases for optimizing the speed regulation capability. The final optimized PMSM is compared with the original one, which shows superiorities in terms of torque, speed regulation range, and efficiency.