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Evaluating the multiphysics performance of an electric motor can be a computationally intensive process, especially where several complex subsystems of the motor are coupled together. For example, evaluating acoustic noise requires the coupling of the electromagnetic, structural and acoustic models of the electric motor. Where skewed poles are considered in the design, the problem becomes a purely three-dimensional (3D) multiphysics problem, which could increase the computational burden astronomically. This study, therefore, aims to introduce surrogate models in the design process to reduce the computational cost associated with solving such 3D-coupled multiphysics problems.

The procedure involves using the finite element (FE) method to generate a database of several skewed rotor pole surface-mounted permanent magnet synchronous motors and their corresponding electromagnetic, structural and acoustic performances. Then, a surrogate model is fitted to the data to generate mapping functions that could be used in place of the time-consuming FE simulations.

It was established that the surrogate models showed promising results in predicting the multiphysics performance of skewed pole surface-mounted permanent magnet motors. As such, such models could be used to handle the skewing aspects, which has always been a major design challenge due to the scarcity of simulation tools with stepwise skewing capability.

The main contribution involves the use of surrogate models to replace FE simulations during the design cycle of skewed pole surface-mounted permanent magnet motors without compromising the integrity of the electromagnetic, structural, and acoustic results of the motor.