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Presents a method for the finite element (FE) analysis of saturation effects in a squirrel‐ cage electrical machine. The proposed mathematical model includes the FE equations of the electromagnetic field, the equations which define the connection of windings, and the mechanical equation. Applies an approach based on a simultaneous solution of these equations, paying special attention to the movement simulation. Applies the time‐stepping method with a fixed grid, independent of the rotar position. In the method the motional effects are simulated by trigonometric interpolation of the results for the previous time step.

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PurposeThe purpose of this paper is to elaborate the algorithm and computer code for the structure optimization of the outer rotor permanent magnet brushless DC motor and to execute optimization of selected motor structure using the non‐deterministic procedure.Design/methodology/approachThe mathematical model of the device includes the electromagnetic field equations with the nonlinearity of the magnetic core taken into account. The numerical implementation is based on the finite element method and stepping procedure. The genetic algorithm has been applied for the optimization. The computer code has been elaborated.FindingsThe elaborated computer software has been applied for the optimization and design of BLDC motors. The elaborated algorithm has been tested and a good convergence has been attained.Originality/valueThe presented approach and computer software can be successfully applied to the design and optimization of different structure of BLDC motors.

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