Design Method and Performance Analysis of High Overload Permanent Magnet Synchronous Motor

To enhance the overload capability of permanent magnet synchronous motors (PMSMs), this article proposes a robust design methodology capable of sustaining stable operation. First, a comprehensive overload design criterion is established based on three key factors: antidemagnetization of the permanent magnets, magnetic saturation margin of the stator, and overcurrent capacity of the windings. Second, by using three types of redundant physical boundaries as convergence criteria, the proposed method replaces full-range nonlinear modeling with a linear analytical model (AM), significantly improving modeling efficiency while ensuring overload feasibility. A PMSM with axial V-shaped surface-mounted magnets is developed, and an AM is derived to reveal the sensitivity of key structural parameters to overload performance. Third, to support design optimization, an improved game-theoretic weighting method is proposed to enhance the MLP-RF surrogate model, enabling accurate nonlinear mapping between structural parameters and overload performance. The RIME algorithm is then employed for efficient multiobjective optimization. Finally, simulation and experimental results confirm that the proposed method significantly improves the motor’s stability and reliability under triple overload, validating its effectiveness and practical applicability.