Multi-Step Design Optimization for the Improvement of an Outer-Rotor Brushless Direct Current Motor

Brushless Direct Current (BLDC) motors have seen significant improvements across various electrical applications. The growing focus on motor design research highlights the BLDC motor's superior efficiency compared to traditional motors, which consume more power. BLDC motors are compact, lightweight, energy-efficient, and easy to control, making them ideal for modern applications. This study aims to enhance BLDC motor design and performance by employing the Taguchi method, Response Surface Methodology (RSM), and Finite Element Method (FEM) for multi-stage optimization. A 26-watt BLDC electric fan motor is the reference model for this study. The Taguchi method helps identify optimization points, guiding further enhancements in the second stage. The study proposes a design with improved output power, torque, and efficiency. The final design achieves a 15% higher energy efficiency than the reference model, with a 10 W increase in output power and a 0.032 Nm increase in maximum torque. The FEM analysis using JMAG software v 21.2 validates the proposed design, which shows improved configurations compared to the reference model, demonstrating the efficiency of the optimization techniques for BLDC motor design.