High power density, low moment of inertia permanent magnet synchronous motor design for applications requiring precise positioning

Permanent Magnet Synchronous Motors (PMSMs) have become one of the indispensable components of modern electric drive systems due to their superior characteristics, such as high power density, energy efficiency, and precise controllability. They are widely preferred in automation systems, electric vehicles, household appliances, and robotic applications, primarily because they can provide stable torque-speed characteristics over a broad operating range and exhibit low acoustic noise levels. The use of permanent magnets on the rotor eliminates the need for additional excitation current to generate the magnetic field, thereby reducing overall system losses and enhancing efficiency. In this study, the electromagnetic and thermal design of a PMSM with 1.5 kW output power, 2.4 Nm rated torque, and 6000 rpm rated speed has been carried out. During the design process, fundamental design parameters such as stator slot geometry, magnet sizing, air-gap optimization, winding arrangement, and material selection were considered, and their effects on torque ripple, efficiency curves, and temperature distribution were analyzed. Electromagnetic analyses evaluated magnetic saturation, flux density distribution, and torque characteristics, while thermal analyses focused on winding temperature rise, magnet thermal limits, and the rotor-stator thermal behavior. The analyses were performed using the Motor-CAD software, and the results were compared with the targeted performance specifications to assess the motor's suitability for industrial application scenarios. Additionally, engineering insights were provided regarding the motor's dynamic response, thermal reliability, and operational stability under continuous operating conditions, and potential optimization opportunities were identified. This work thus presents a holistic design approach that simultaneously meets both electromagnetic and thermal performance criteria.