Optimal design of electric machine with efficient handling of constraints and surrogate assistance

An optimal electric machine design task can be posed as a constrained multi-objective optimization problem. While the objectives require time-consuming finite element analysis, constraints, such as geometric constraints, can often be based on mathematical expressions. This article investigates this mixed computationally expensive optimization problem and proposes a computationally efficient optimization method based on evolutionary algorithms. The proposed method always generates feasible solutions by using a generalizable repair operator and also addresses time-consuming objective functions by incorporating surrogate models for their prediction. The article successfully establishes the superiority of the proposed method over a conventional optimization approach. This study demonstrates how a complex engineering design task can be optimized efficiently for multiple objectives and constraints requiring heterogeneous evaluation times. It also shows how optimal solutions can be analysed to select a single preferred solution and harnessed to reveal vital design features common to optimal solutions as design principles.