Abstract
Stepper motors are extensively used in various automated systems, notably hybrid stepper motors (HSMs), renowned for their high torque density. Optimizing and improving their performance and torque density is highly beneficial. The first step in motor optimization is to perform a sensitivity analysis to identify the parameters most significantly affecting motor performance and torque density. Using Ansys Maxwell, a finite element method (FEM) software, we modeled and analyzed a commercially available HSM. After validating the computer model’s accuracy, we investigated the motor’s sensitivity to various parameters and discussed their effects on performance. Our findings highlight the significance of parameters such as air gap, magnet diameter, wire-turn numbers in the coils, and the shapes of the rotor and stator teeth in influencing HSM sensitivity—conversely, factors like magnet height and stator pole thickness exhibit negligible impact on motor performance.