Predictive Modeling and Comparative Performance Analysis of PMSM Designs in EV and Industrial Drives

Permanent Magnet Synchronous Motors (PMSMs) are increasingly adopted in electric vehicles (EVs) and industrial drives due to their high efficiency and torque density. However, performance varies with motor topology, operating conditions, and thermal management. This study presents a comparative evaluation of three PMSM types—Axial Flux, Interior Permanent Magnet (IPM), and Surface Permanent Magnet (SPM)—using a subset of 1,000 records from the PMSM Smart Control Dataset (Kaggle), containing 15 electrical and thermal parameters. Statistical analysis and comparative plots were used to examine efficiency, torque–speed characteristics, current and voltage demand, and temperature rise under different load conditions, cooling methods, and application modes. Results show that SPM motors achieve the highest efficiency (75.9%) and superior thermal stability, making them suitable for sustained EV traction, while IPM motors provide strong torque density and wide-speed performance. Axial Flux motors, with compact geometry and steady torque, are most advantageous in constant-torque industrial drives. In addition, predictive modeling was employed to estimate efficiency from electrical, thermal, and categorical descriptors. A linear regression model achieved R² ≈ 0.62 on the test dataset, with stator/rotor temperatures, current, and operating mode identified as the most influential predictors. These findings demonstrate that combining comparative evaluation with predictive modeling supports optimal PMSM selection and enables lightweight, real-time efficiency estimation, contributing to intelligent control strategies for sustainable mobility