The finite element method (FEM) is typically used in the process of motor design. However, the FEM requires much computation time. Therefore, decreasing the number of FEM simulations may also decrease the simulation cost. Several optimal design methods overcoming this problem have been recently studied. This paper investigates the optimal design of the magnet pole of a brushless DC motor through reducing simulation cost. The optimization minimizes the magnet volume and limits the average and cogging torques to certain values. In this paper, the response surface methodology and Taguchi's table for decreasing the number of FEM simulations are used to approximate two constraints. The optimization result shows that the presented strategy is satisfactorily performed.
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