Optimization and Material Enhancement Framework for Improving PSC Motor Efficiency Toward IE2/IE3 Standards

This paper presented an optimization and material enhancement framework for improving the efficiency of a 1 HP Permanent Split Capacitor (PSC) motor toward IE2/IE3 efficiency classes. The proposed approach integrated Design of Experiments (DOE) using the Taguchi method with loss-based analysis to investigate the influence of key design parameters, including stator stack height, capacitor value, and silicon steel grade on PSC motor efficiency. Taguchi L8 and L9 orthogonal arrays were applied to evaluate parameter interactions and identify dominant factors affecting motor performance. To enhance predictive capability, a Response Surface Methodology (RSM) model was developed based on experimental data to establish the relationship between design variables and motor efficiency within the investigated operating range. The resulting efficiency map was used to identify high-efficiency operating regions and support practical PSC motor design evaluation. Experimental validation under multi-load operating conditions confirmed that the optimized motor achieved an efficiency improvement from 76.1% to 80.4% (4.6% absolute increase), with less than 2% deviation between simulation and experimental results. The optimized motor also demonstrated improved operating behavior across varying speed and load conditions while maintaining practical operating stability. The proposed framework provided a practical and simplified approach for PSC motor efficiency improvement under the investigated operating conditions and offers an alternative to computationally intensive optimization approaches for industrial motor applications.