A novel automated design optimization procedure based on the application of an ultrafast computationally efficient finite-element analysis (CE-FEA) for current-regulated synchronous reluctance machines supplied from power electronic converters is proposed. The CE-FEA uses only a minimum number of magnetostatic solutions in order to comprehensively evaluate performance, including ripple torque and core losses. The optimization algorithm is based on differential evolution, and uses as independent variables the torque angle and ratios for a generic rotor topology with four flux barriers. Two problems, one with two and the other with three objectives, are studied and results are compared. Global performance indices and objectives incorporate the effect of average torque output, losses, torque ripple, and power factor at fixed cost. It is shown that through optimal studies with more than 5000 candidate designs, high output power, high efficiency, and low torque ripple can be achieved, while the relatively low power factor remains an inherent limitation of synchronous reluctance technology. Simulations are validated versus tests from a 10-hp 1800-r/min prototype.

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Published in IEEE Transactions on Industry Applications, v. 52 , issue 6.

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The document available for download is the authors’ manuscript version that is accepted for publication. The final published version is copyrighted by IEEE and available as: Y. Wang, D. M. Ionel, V. Rallabandi, M. Jiang and S. J. Stretz, ”Large-Scale Optimization of Synchronous Reluctance Machines Using CE-FEA and Differential Evolution,” in IEEE Transactions on Industry Applications, vol. 52, no. 6, pp. 4699-4709, Nov.-Dec. 2016, doi: 10.1109/TIA.2016.2591498

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The sponsorship provided to the group at University of Wisconsin - Milwaukee by Regal Beloit Corp., ANSYS, Inc., and Motor Design, Ltd. is gratefully acknowledged.