Design and Optimization of a Slotless PMSM With Hexagon Distributed FPCB Winding

TY - JOUR

T1 - Design and Optimization of a Slotless PMSM With Hexagon Distributed FPCB Winding

AU - Zhao, Jing

AU - Ding, Yu

AU - Wang, You

AU - Deng, Lufan

AU - Yang, Lei

AU - Liu, Xiangdong

AU - He, Wei

N1 - Publisher Copyright: © 1972-2012 IEEE.

PY - 2026/5/1

Y1 - 2026/5/1

N2 - In this paper, the winding loss problem and optimization method of flexible printed circuit board (FPCB) hexagonal slotless permanent magnet synchronous motor (PMSM) are studied. Due to the particularity of the motor winding structure, the existing direct winding calculation method is difficult to apply to the hexagonal winding structure, the general multi-objective optimization design method based on 3D finite element method (FEM) is often time-consuming and difficult to implement. In order to solve the above problems, firstly, the effects of pole-slot matching and stator-rotor parameters on electromagnetic performance is analyzed. The propose analytical models for winding eddy current loss, circulating current loss, and electromagnetic torque are established and validated using 3D FEM and experiments. Then, in the optimization of winding connection mode, the winding loss of different connection modes is calculated, and the connection mode with the smallest loss is selected as the optimal scheme. Finally, the fitting function is established for the winding copper loss analysis model as the optimization objective function, the NSGA-II multi-objective optimization algorithm and TOPSIS comprehensive decision are used to optimize the winding shape with the best performance of this motor.

AB - In this paper, the winding loss problem and optimization method of flexible printed circuit board (FPCB) hexagonal slotless permanent magnet synchronous motor (PMSM) are studied. Due to the particularity of the motor winding structure, the existing direct winding calculation method is difficult to apply to the hexagonal winding structure, the general multi-objective optimization design method based on 3D finite element method (FEM) is often time-consuming and difficult to implement. In order to solve the above problems, firstly, the effects of pole-slot matching and stator-rotor parameters on electromagnetic performance is analyzed. The propose analytical models for winding eddy current loss, circulating current loss, and electromagnetic torque are established and validated using 3D FEM and experiments. Then, in the optimization of winding connection mode, the winding loss of different connection modes is calculated, and the connection mode with the smallest loss is selected as the optimal scheme. Finally, the fitting function is established for the winding copper loss analysis model as the optimization objective function, the NSGA-II multi-objective optimization algorithm and TOPSIS comprehensive decision are used to optimize the winding shape with the best performance of this motor.

KW - Slotless permanent magnet synchronous motor (PMSM)

KW - end magnetic flux leakage

KW - hexagon flexible printed circuit board (FPCB) winding

KW - optimization algorithm

KW - the winding loss

UR - https://www.scopus.com/pages/publications/105018764249

U2 - 10.1109/TIA.2025.3621572

DO - 10.1109/TIA.2025.3621572

M3 - Article

AN - SCOPUS:105018764249

SN - 0093-9994

VL - 62

SP - 3802

EP - 3811

JO - IEEE Transactions on Industry Applications

JF - IEEE Transactions on Industry Applications

IS - 3

ER -