Torque Optimization of Axial Dual-Salient Synchronous Reluctance Motor Based on Orthogonal Experimental Design

This paper presents an axial flux dual-salient synchronous reluctance motor to address the inherent limitations of conventional synchronous reluctance motors (SynRMs) and switched reluctance motors (SRMs). While SynRMs suffer from complex flux barriers that reduce mechanical strength and increase losses, SRMs exhibit high torque ripple and acoustic noise. The proposed motor combines the advantages of simple control and low torque ripple from synchronous motors with the high mechanical strength and reliability of switched reluctance motors. A finite element model with 30-slot, 5-pole-pair configuration is established, and orthogonal experimental design methodology is employed to optimize four critical rotor parameters: slot width, air gap length, chamfer length, and chamfer thickness. Variance analysis reveals that chamfer thickness has the most significant impact on torque ripple and efficiency. Simulation results demonstrate that the optimized design achieves a 3% improvement in average torque and a remarkable 61.2% reduction in torque ripple compared to the baseline configuration. The proposed optimization methodology provides valuable theoretical foundation and practical guidance for axial flux motor engineering design and applications.