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In this paper, an interior permanent magnet (IPM) synchronous machine with multiflux barriers is proposed to meet the wide speed regulation application requirements of electric vehicles. Based on the flux barrier characteristic, an electromagnetic–mechanical coupling optimization strategy is employed for the machine design. In order to facilitate the optimization design, the rotor barriers are divided into two optimization zones, the maximum stress zone and the maximum deformation zone. The electromagnetic–mechanical coupling optimization strategy is divided into two stages accordingly. In the first stage, the machine is regarded as a synchronous reluctance machine by ignoring permanent magnets, where the dimensions of the arc-shaped barriers are optimized to achieve a large reluctance torque and small stress. In the second stage, the dimensions of the arc-shaped PMs and the elliptical barrier are optimized with three objectives of minimum torque ripple, minimum flux linkage, and minimum deformation. After machine optimization, the comparison investigations are carried out on the basis of finite-element analysis by considering both the electromagnetic performances and mechanical performances.

Electromagnetic–Mechanical Coupling Optimization of an IPM Synchronous Machine with Multi Flux Barriers