Abstract
<title>Abstract</title> <p>Interior permanent magnet Vernier machineries are better in low-speed torque to propel electrically, or direct-drive. Their operation limited by low density of torque and high torque ripple since the multi-harmonic interactions are complex. Proposed model suggests a new multi-objective design approach to bring a systematic solution to these shortcomings. Its new features are the explicit mathematical combination of permanent-magnet-reluctance and magnet-reaction harmonic effects in a larger Analytical Permeance Unit (APU) model, with complete derivation. This is incorporated in closed loop structure of combining fast APU optimization with manufacturing-tolerance robustness through Monte-Carlo simulations and coupled multi-physics validation. Additionally, the work proposes a novel topology that is characterized by a hybrid irregular-teeth stator and an asymmetrical spoke/V-shaped rotor. An experimental test on a pseudo-fabricated 36 slot prototype showed a torque density of 26.8 kNm/m 3, which is 20–30% better than the earlier designs. Torque ripple was minimized to 4.7%, cogging torque was not more than 0.8 Nm and peak efficiency was 96.2%. The machine was also able to operate at over 150% rated torque up to 30 minutes without thermal or structural constraints. This design route offers a strong, high-quality design route to interior permanent magnet Vernier machines which is a major breakthrough in the efficient electrification of electric vehicles, wind turbines, and industrial drives.</p>