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This study aims to design the rotor geometry of switched reluctance motor (SRM) in a completely flexible way. In the proposed method, there is no default geometry for the rotor. The initial geometry of the rotor can start from a circle or any other shape and depending on the required performance takes the final shape during the optimal design. In this way, the best performance, possible with geometric design, can be achieved.

The rotor boundary of a 4/2 SRM is defined by a few B-splines. Some control points are located around the rotor and changing their locations causes customized changes in the rotor boundary. Locations of these points are defined as design variables. A 2-D finite element analysis using MATLAB/PDE is applied to the SRM model and sensitivity analysis is used to optimization design by means of minimizing of objective function.

The proposed method has many more capabilities for matching different objective functions. For the suggested objective function, while the conventional rotor torque profile difference with the desired torque profile reaches 40%, this difference for B-spline rotor is about 17%. Experimental results from a prototype motor have a close agreement with analysis results.

The B-splines have been used to design machines and electromagnetic devices. However, this method is used for the first time in design of the whole rotor of a SRM.