Permanent magnet synchronous machines (PMSMs) with an overhang structure can increase power density by compensating for the increased magnetic energy of permanent magnets. To analyze the overhang structure, a three-dimensional (3D) analysis of PMSMs is essential. However, 3D analysis takes a long time and the modeling process is complicated in the initial design stage. To overcome these problems, a magnetic equivalent circuit technique is applied to the 2D model. In this paper, an optimal design method for PMSMs with an overhang structure is proposed based on the semi 3D magnetic equivalent circuit (MEC) and random walk method. By using semi 3D MEC, it is possible to quickly analyze PMSM and obtain accurate electromagnetic analysis results considering the overhang effect. Moreover, the volume and weight of PMSM can be minimized by optimizing the rotor’s four design parameters using a random walk algorithm. To obtain high efficiency, the objective function is selected so that copper loss is minimized under the same constraints. The validity of the proposed design technique is verified by comparing the analysis results of semi 3D MEC and 3D finite element method for the derived optimal model.

In contrast to internal combustion engine vehicles, electric vehicles (EVs) obtain the power required for the compressor of air conditioning system from an electric source. Therefore, an optimal design for electric motor, the main component of an electric compressor, is essential for improving EV mileage. A multi-objective optimal design is required because the characteristics of the motor are in a trade-off relationship with each other. When the finite element method (FEM) is used, multi-objective optimal designs for the motor take a significant amount of time because of the diversity analyses required for the optimal-model search. To solve this problem, in this study, a multi-objective optimal design method of an SPMSM for an EVs air conditioner system compressor was proposed and applied using the NSGA-II and an analytical method. The validity of the proposed method was confirmed by comparing the characteristics of the optimal design model with those of the initially designed model.