The system specifications should be considered in the practical design of linear machines, albeit mostly neglected in the previous studies. The main objective of this article is to propose a systematic design method of a coreless-type permanent magnet linear synchronous machine (PMLSM), satisfying all the constraints resulting from the system specifications. Based on the trapezoidal motion profile, an electromagnetic design model is developed by utilizing the 2-D field solutions and energy conversion principle. The thermal effects are incorporated into the design model by measuring the hot-spot temperature of the static winding coil, thereby setting the upper limits of current density. The differential evolution (DE) is then applied to the design model to search for optimal solutions without violating any of the constraints. As a result, the proposed model combined with DE provides the Pareto-optimal front belonging to the feasible regions where all system specifications (e.g., acceleration profile, maximum speed, maximum allowable temperature, load mass, and supply voltage) are satisfied. Finally, the validity of the design model is verified by both the finite element (FE) and experimental results.
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