Design and Optimization of a Low-Cost Hybrid-Pole Rotor for Spoke-Type Permanent Magnet Machine

In this article, a novel spoke-type permanent magnet (PM) machine with two types of PM materials is proposed to reduce the cost. In order to improve torque density and reduce torque ripple, the multi-objective optimization combined finite element method (FEM) and genetic algorithm (GA) are used. In addition, the electromagnetic performances of the novel spoke-type PM machine, including no-load air-gap flux density, electromagnetic torque, torque ripple, efficiency, and cost are compared with the conventional spoke-type PM machine. It is demonstrated that the novel spoke-type PM machine obtains a 1.5% lower torque ripple and 36% lower cost, and the torque density is 4.3% lower than the conventional spoke-type PM machine. Meanwhile, the novel spoke-type PM machine has lower core loss and higher efficiency. Finally, a 40 kW spoke-type PM machine is manufactured to verify the analyzing method. Experimental results demonstrate that the proposed machine exhibits high torque density and low cost in the application of electric vehicles (EVs).