This study focuses on optimisation design of permanent magnet linear synchronous motors that are applied in laser engraving machines with no cutting force. Traditional analytical optimisation method based on magnetic field with particle swarm optimisation algorithm was introduced to obtain the best combination of motor structure parameters. By contrast, the novel optimisation design method-Taguchi method based on orthogonal array was proposed to optimise the thrust and thrust ripple. After the design of experiments using finite-element analysis, the relative importance of each design parameter was estimated in detail. Experimental results of prototype can certify the superiority and validity of Taguchi optimisation method.

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