In this paper, the design and optimization of 4.5 kW inner rotor permanent magnet synchronous motor (PMSM) with 400 rpm nominal speed was carried out for belt drive elevator systems. Unlike traditional methods, the integration of the motor into the elevator carrier system is provided directly on the rails. Thus, high cost and complex machine chassis constructions are eliminated. The elevator loads accumulated on the machine were properly transmitted to the building and the ground. The electrical and magnetic modeling of the PMSM was carried out considering the volume constraints that emerge according to the mechanical design. The two most important criteria to be considered in elevator traction motors are providing high efficiency and passenger comfort. In line with these objectives, a design with efficiency above 91% and torque ripple below 1% is presented. Based on the acquired limit values and using the finite element method (FEM), the optimization of parameters such as the slot opening, magnet thickness, embrace, stator tooth thickness and air gap was conducted via genetic algorithm. In addition, step skewing of magnets was applied to the optimized model to reduce torque ripple. According to the results, 18 slot-20 pole PMSM with 0.61% torque ripple and 90.97% efficiency has been obtained. The designed PMSM was produced and tested using an electrical motor test setup. Based on the test results, the efficiency and cogging torque were obtained as 89.98% and 0.78 Nm (pk2pk) respectively. Thus, the FEM analysis solutions are verified by the test results.

This paper proposes a 2 kW in-wheel brushless direct current (BLDC) motor design for a light electric vehicle (EV). The EV is designed for a predefined route in electric vehicle races. The BLDC motor was directly mounted into the vehicle's wheel rim. Initially, dynamic model of EV was calculated according to vehicle characteristics. The motor's slot/pole ratio was selected as 36/32. The designs for the stator, rotor, and magnets were subsequently developed based on the motor's boundary dimensions, aiming for low cogging torque and high efficiency. To achieve this, the distance between stator tooth tips was optimized. The design was validated through 2D finite element analyses, followed by the motor's production. Performance tests conducted with the experimental setup confirmed that the design matches the experimental results.

Elevator traction motors are critical components of elevator systems. After the structural analysis of the traction motor, it is necessary to proceed to the production processes for the comfortable and safe use of elevator systems. In this study, the static load values for bearing lifetime calculation, belt selection, and finite element analyses (FEA) were determined. According to calculated loads; materials, bearings, belt, pulley, brake, and encoder were selected. In order to obtain a design in accordance with elevator standards, motor parts were examined for structural analysis. Finite element analyses were carried out according to the determined maximum static load values, and a new belt elevator traction motor design that provides the safety coefficients has emerged. When the FEA analysis results of bending moments are examined; the maximum Von Mises stress acting on the motor frame and shaft was obtained 17.1 MPa and 27.62 MPa respectively. The maximum Von Mises stress was obtained under the torsional moment as 71.4 MPa and the shaft is 6.1 times safe against a torsional moment. This value is the minimum safety factor of the designed system and safety factors of bending moments are higher than this value. The designed elevator machine has got 12.9 kW rated power, 1.6 m/s cabin speed, and 1175 kg carrying capacity. The advantage of the proposed design is to eliminate the casting process with modular structure via double side belt system. The prototype of the designed motor was produced and it was observed that the motor provided the desired constraints as a result of the loading experiments.

This study presents the design, modeling, and prototyping of an external rotor permanent magnet synchronous motor (ER-PMSM) specifically for elevator traction systems. The external rotor design aims to surpass the efficiency of conventional inner rotor gearless elevator traction motors. A commercially available 4 kW inner rotor permanent magnet synchronous motor (IR-PMSM) was selected for comparative analysis. Critical parameters, including stator tooth tip thickness, slot tip radius, slot height, stator yoke height, stator tooth thickness, and the number of turns per phase, were optimized to enhance efficiency. The artificial bee colony (ABC) algorithm was utilized for the first time to determine the optimal configuration of an external rotor PMSM. The prototype was fabricated and subjected to rigorous testing using a dedicated electrical motor test setup. Comparative results demonstrated a significant improvement in efficiency for the ER-PMSM over the IR-PMSM, with the efficiency increasing from 72.5% to 84.67% at nominal operating conditions.

This study presents a stator-focused electromagnetic optimization of a 350 W, 27-slot, 30-pole outer-rotor brushless direct current (BLDC) motor developed for electric scooter applications. Unlike conventional redesign approaches that modify rotor topology or overall motor dimensions, the proposed methodology preserves the rotor structure and external geometry of a commercially validated reference motor and improves performance primarily through targeted stator geometric refinement, with minor adjustments in the winding configuration. A two-stage optimization strategy combining parametric analysis and genetic algorithm (GA)-based multi-objective optimization is implemented to minimize cogging torque and torque ripple while maximizing efficiency. Finite element analyses (FEA) were conducted to evaluate back electromotive force (back-EMF) characteristics, magnetic flux density distribution, torque behavior, and current density. Experimental validation confirms a 54.86% reduction in cogging torque (from 257 mNm to 116 mNm), a 19.6% decrease in torque ripple, a 6.17% reduction in maximum current density, and a 2–3% improvement in efficiency within the nominal load range (5.2–6.45 Nm), reaching 85.69% efficiency at 350 W output power. The results demonstrate that systematic stator geometry optimization, supported by minor winding modifications, can significantly enhance efficiency, torque smoothness, and thermal margin without increasing motor size, rated power, or manufacturing complexity. This work provides a practical and manufacturable design pathway for high-performance outer rotor BLDC motors in light electric vehicle (LEV) propulsion systems.