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This paper deals with the optimization for performance and cost of the low-power permanent magnet synchronous machines used in automotive applications with focus on particularities of high-volume mass production and the constraints that arise. The described optimization loop is used to compare different 12/8 and 12/10 designs of interior permanent magnet (IPM) type. After showing that the 12/10 IPM exhibits the best performance-cost ratio, results obtained at different stages in the process (i.e., sensitivity analysis and constrained single-/multiobjective optimizations), for both no-load and load case, are provided. Finally, different aspects for reducing the complexity of the multidomain optimization problem (e.g., 3-D effects, iron losses, and effects of tolerances on the motor characteristics) are addressed.

Optimization of Low-Power Brushless PM-Machines for Automotive Applications With Focus on High-Volume Mass Production