Optimization of rotor and stator geometries to reduce the specific time and space order electromagnetic forcing in IPMSM

With the rapid electrification of the automotive sector, the NVH performance of Electric Vehicles has become an important design consideration, particularly due to the absence of ICE masking noise. In BEV applications with EDUs using IPMSM, electromagnetic forces acting on the stator teeth are the primary source of electromagnetic vibration and acoustic noise. This paper presents a multi-objective optimization methodology focusing on rotor and stator geometry parametrization, such as slot opening, tooth depth, pole v angle, to tackle the specific forcing orders. The workflow integrates FEA software to simulate electromagnetic performance across a range of operating points. Constraints are applied to maintain torque, power and efficiency within tolerances of the baseline design. modeFRONTIER advanced post-processing tools, such as Parallel Coordinate plots and Pareto Front analysis, are used to visualize the trade-offs between force reduction and electromagnetic performance. The results validate that selected geometric modifications can reduce exciting forces without compromising the motor’s efficiency, power or torque.