Finding an optimally designed synchronous reluctance machine with desired performance among all possible combinations of the stator and rotor with different shapes of barriers requires long execution time, which is an overwhelming task. Selecting the number of flux barriers, for instance, in accordance with the pre-designed stator has a significant effect on the torque ripple. To tackle these issues, this study presents a comprehensive design procedure of an external rotor synchronous reluctance machine suitable for an electric bike application that includes considerations such as electromagnetic and mechanical aspects. Dimensions of the internal stator with tapered slots are calculated. Additionally, a global parameter, insulation ratio in the q-axis, is used to link the microscopic parameters. Seeking for the optimal design through the insulation ratio effectively reduced the number of geometric parameters involved in the rotor shape optimisation. The preliminary rotor design is used to run multi-objective optimisation to provide further improvement to the average torque and torque ripple. Utilising the finite-element method, thermal and structural analyses are conducted to guarantee the safe operation of the designed motor under a steady-state condition. Finally, measurement results of a 250 W-fabricated motor are compared with the predicted results, which validate the effectiveness of the proposed method.
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