Evaluation of Multi-Tooth Stator-Rotor Modifications for Torque Enhancement in 6/4 Switched Reluctance Motors

Abstract

The switched reluctance motor (SRM) is a promising candidate for high-torque electric drive applications due to its simple construction, high reliability, and cost-effectiveness. However, conventional SRM designs are limited by torque ripples, acoustic noise, and magnetic flux saturation, which constrain their performance. This study introduces a Teeth-on-Tooth (TeOnTo) configuration, in which each stator and rotor pole is subdivided into multiple smaller teeth to concentrate magnetic flux and shorten the flux path. A systematic finite element analysis (FEA) using Siemens Simcenter MAGNET was carried out on 36 stator–rotor combinations, of which 19 representative models are reported in detail to investigate the influence of tooth count and slot depth on torque, acceleration, efficiency, and weight reduction. Results show that moderate tooth segmentation yields substantial improvements in torque per unit volume, with the 18/16 configuration achieving a 203% peak torque increase over the baseline 6/4 SRM and over 1 kg weight savings. Excessive segmentation approaches material saturation, resulting in diminishing or negative performance gains. While the findings are currently based on simulation, the observed trends are expected to generalize to other SRM topologies with similar materials and operating conditions. The proposed TeOnTo approach offers a practical and scalable pathway to improve SRM torque capability, acceleration, and efficiency while reducing material usage, making it attractive for high-performance electric vehicle and industrial drive systems.

Keywords

switched reluctance motor Teeth-on-Tooth (TeOnTo)design optimization torque enhancement starting torque improvement flux density finite element analysis electric vehicle drives

Introduction

The electric vehicle (EV) sector is expanding rapidly, driving demand for electric motors that combine high performance with cost-effective manufacturing. Among various motor types, switched reluctance motors (SRMs) have attracted increasing interest due to their simple construction, fault tolerance, and the absence of costly permanent magnets. Although SRMs already offer competitive torque and efficiency, their performance can be significantly enhanced through targeted geometric modifications. While this study frames the work within the context of electric mobility, it is recognized that conventional SRMs face challenges such as acoustic noise, which can limit their adoption in passenger EVs without additional mitigation measures. However, the high torque density, robustness, and cost advantages of SRMs make them equally attractive for other sectors where noise is less critical, such as agricultural machinery, tractors, and industrial traction drives. The design principles and findings presented here are therefore applicable to a broad range of high-torque electric drive applications, extending beyond the EV domain.

One widely explored approach is to increase the number of teeth in the stator, which raises the local flux density and can lead to substantial torque gains.^1–3 However, earlier studies^1,3 also report that beyond a certain threshold, tooth-tip saturation limits further improvement. This highlights a central challenge: how to maximize torque output through tooth geometry optimization without driving the core into saturation. Slot depth is another critical factor, influencing both maximum and average torque,² yet its interaction with multi-tooth designs has not been systematically studied. Recent work by Davarpanah et al.⁴ demonstrated that optimal segmentation and winding configurations can yield significant performance gains in unconventional SRM topologies, underscoring the need for systematic mapping across a broader design space.

Past research has investigated diverse structural modifications to address SRM limitations. Segmented stator and rotor designs⁵ have shown improved starting torque, stability, and response time. Noise reduction strategies include stator pole bridges,⁶ trapezoidal pole geometries,⁷ and pole tip shaping,⁸ while rotor geometry changes such as lamination stacking⁹ or punched holes¹⁰ have been used to reduce torque ripple. Alterations to the stator back iron,¹¹ skewed rotor configurations,^12,13 and hybrid excitation with permanent magnets¹⁴ have also been explored for efficiency enhancement. Other studies examined pole shoe shaping in outer rotor machines,¹ axial flux configurations,¹⁵ and tooth pitch–airgap optimization.³

Recent advances in system-level optimization have further highlighted the importance of holistic design approaches for SRMs. Tzouvaras et al.¹⁶ provides a comprehensive review of current trends in switched reluctance machine optimization, emphasizing the shift towards integrated design methodologies that consider both machine and controller parameters simultaneously. This trend aligns with the TeOnTo approach presented here, which seeks to optimize torque density through geometric modifications while maintaining design simplicity. The design principles and findings presented here are therefore applicable to a broad range of high- torque electric drive applications, extending beyond the EV domain. Recent experimental validation work by Bhaktha et al.¹⁷ on e-rickshaw applications demonstrates the practical viability of optimized SRM designs in real-world electric vehicle scenarios, supporting the broader applicability of systematic design improvements like TeOnTo.

Despite these advances, two important gaps remain. First, existing “split tooth” or “divided pole” approaches tend to focus on isolated configurations and do not map performance trends across a full range of tooth counts and slot depths.^1–4^,18,19 Second, few works jointly consider torque improvement and weight reduction, even though both are critical in applications ranging from electric mobility to industrial and traction drives.^20,21

A comparison of selected prior SRM multi-tooth or slotted-structure designs is presented in Table 1. This summary highlights key differences in geometry, performance, and limitations, positioning the proposed TeOnTo approach in relation to existing methods.

Table 1.

Comparison of TeOnTo with related multi-tooth and slotted-structure designs

Design approach	Description	Key performance effects	Limitations
Divided tooth (outerrotor)¹	Main pole split into multiple narrow teeth	Increases local flux density, improves torque	Early saturation at tooth tips when teeth per pole exceed optimal value
Slotted stator tooth ²	Slots introduced into stator tooth face	Raises torque production, especially for high-load applications	Increased core loss and manufacturing complexity if slot depth excessive
Multiple toothper stator pole ³	Several smaller teeth per pole in stator	Improves mean torque; allows airgap permeance shaping	Diminishing returns and torque drop beyond optimal segmentation
Teeth-on- Tooth (TeOnTo) (this work)	Smaller additional teeth added onto main pole surface without full pole split	Concentrates flux into narrow tooth tips, shortens local flux path, manages saturation effectively	Minimal; preserves structural integrity and reduces manufacturing complexity compared to split-tooth

In contrast to divided-tooth and deep-slot stator designs, which may suffer from premature saturation or increased manufacturing complexity, the TeOnTo approach offers a balance between torque enhancement and structural simplicity. Unlike noise-mitigation methods such as skewed rotors or stator bridges, TeOnTo primarily targets torque density improvement while still maintaining acceptable acoustic behavior. Furthermore, by avoiding permanent magnets, as used in hybrid excitation designs, TeOnTo preserves the cost and supply-chain advantages of conventional SRMs. This positions TeOnTo as a lightweight, manufacturable, and cost-effective option for highly torque applications.

This study addresses these gaps through the introduction of a Teeth-on-Tooth (TeOnTo) configuration, in which each main pole of the stator or rotor is fitted with multiple smaller teeth. By concentrating the magnetic flux into narrower tooth faces and shortening the flux path, this design has the potential to increase torque per unit volume while reducing overall material usage. This systematic FEA-based approach is consistent with recent optimization frameworks that emphasize robust simulation methodologies for SRM design evaluation.²² The comprehensive nature of our 36-configuration analysis provides the extensive dataset necessary for identifying optimal design trade-offs. The resulting performance map identifies optimal configurations and quantifies the trade-offs, positioning TeOnTo as a practical and effective extension to the SRM design toolbox.

The fundamental torque development in SRMs is directly related to the rate of change of inductance with rotor position and the resulting flux density distribution. The analytical formulation and its relation to tooth geometry are presented in Methodology section, serving as the theoretical basis for the proposed design modifications.

Methodology

Theoretical basis of torque enhancement

Starting torque is critical for the load-driving capability of SRMs, and this research focuses on design modifications aimed at improving both the starting torque and transient performance (acceleration) of the motor. A comprehensive discussion on the construction and operation of SRMs is presented in.²³ Figure 1 illustrates a 3-dimensional view of an SRM, featuring 6 stator poles and 4 rotor poles, modeled using finite element analysis (FEA) software.

Figure 1.

Arrangement of stator, rotor, and coils in SRM.

The fundamental equation of the developed torque in SRM can be expressed to explain the dependence on flux density to decide the increase in torque of this machine as,

T_{e} = \frac{P}{ω} = V . i \cdot \frac{\partial t}{\partial θ} = N . i \cdot \frac{\partial φ}{\partial θ}

(1)

From Equation (1), the specific output torque (torque per unit volume) can be expressed as follows:

T_{v o l} = \frac{T_{e}}{v} = \frac{N . i}{v} = \frac{\partial φ}{\partial θ} = \frac{N . i . A}{v} \cdot \frac{\partial B}{\partial θ}

(2)

T_{v o l} = C \cdot \frac{\partial B}{\partial θ}

(3)

where P – Power, ω – Speed, V – Voltage, i – Current, N – Number of turns, φ – Flux, θ – Position, A – Cross-sectional Area, B – Flux Density and C is a constant.

From Equations (2) and (3), it is evident that an increase in flux density is the only way to enhance the torque per unit volume. Since flux density is inversely proportional to the area of the tooth face, a reduction in the area due to the slotted structure leads to an increase in flux density. This design modification, which involves incorporating slots in the structure, effectively concentrates the magnetic flux, thereby improving the overall torque generation capabilities of the motor.

Unmodified version of classical SRM

To thoroughly validate the improvement in torque generated by the motor, a 6/4 switched reluctance motor (SRM) is chosen as the reference model. This model, which consists of 6 stator poles and 4 rotor poles, serves as the baseline for comparison. All design modifications intended to enhance torque generation are applied to this reference 6/4 SRM, and the resulting performance is compared with that of the unmodified version of the same motor.

The unmodified SRM, shown in Figure 2, serves as the starting point for the evaluation. The performance metrics of the unmodified motor are outlined in Table 2, including key parameters such as torque output, maximum coil currents, and other relevant characteristics. These initial results serve as a benchmark, providing a reference for evaluating the effectiveness of the design modifications. The design modifications introduced in the study include changes aimed at improving torque density and enhancing the overall performance of the SRM. These modifications are applied to the 6/4 SRM to explore how each design change influences the motor's torque output and efficiency.

Figure 2.

Unmodified SRM as reference model.

Table 2.

Unmodified SRM results

Model	Torque (Nm)	Average Torque (Nm)	Current (A)	Speed (rpm)	Acceleration (rad/s ² )
6/4	23.92	9.368	18.71	537.2	4454

In addition to the performance data from Table 2, the motor design parameters are crucial for understanding the changes in the machine's structure and how these modifications impact its operation. Table 3 provides the specific design parameters of the 6/4 SRM, including dimensions and other essential details. These parameters are key to assessing the motor's performance and are used to ensure that the modified design remains within operational constraints while maximizing torque production.

Table 3.

SRM design parameters

Motor design parameter	Values
Inner diameter of stator	82.67 mm
Outer diameter of stator	150 mm
Outer diameter of rotor	81.67 mm
Inner diameter of rotor	15 mm
Airgap length	1 mm
Stack length	300 mm
Number of stator poles	6
Number of rotor poles	4
Stator yoke thickness	8 mm
Pole arc to pole pitch ratio	0.515
Winding type	Concentrated

By comparing the results from the modified and unmodified 6/4 SRM models, the research aims to quantify the improvements in torque and performance brought about by the proposed design modifications. This approach allows for a detailed understanding of the effects of each modification on the motor's overall performance, providing insights into how design changes can lead to better performance in switched reluctance motors. The use of the unmodified SRM as a benchmark ensures that the observed improvements can be attributed directly to the design modifications and not to variations in motor type or configuration.

The static torque characteristic of the unmodified SRM is illustrated in Figure 3. This figure depicts the relationship between the torque produced by the motor and its operating conditions, such as the rotor position and current. The static torque characteristic provides critical insight into the motor's performance under steady-state conditions and serves as an essential reference for understanding how the motor behaves without any design modifications.

Figure 3.

Unmodified SRM static torque characteristics.

In the Figure 3, the torque is plotted as a function of the rotor position, typically showing a non-linear behavior due to the nature of the switched reluctance motor. This curve illustrates key performance indicators, such as the peak torque and the regions where the motor produces maximum or minimum torque.

Teeth on tooth design modifications of SRMs

The design of the motor shape is crucial for effectively improving the performance of a switched reluctance motor (SRM). To achieve cost-effectiveness and reduce material usage, this research focuses on evaluating the performance of a three-phase 6/4 SRM, which is considered one of the simplest yet most effective SRM configurations. The study investigates design modifications that involve multiple teeth on a single tooth on both the rotor and stator, referred to as “Teeth on Tooth” (TeOnTo) modifications. Table 4 summarizes the various stator and rotor combinations of the Teeth on Tooth (TeOnTo) models, to improve the performance of the SRM.

Table 4.

Combination of TeOnTo models

Sl. No.	Stator TeOnTo modifications	Rotor TeOnTo modifications
1	No TeOnTo	2 teeth
2		3 teeth
3		4 teeth
4		5 teeth
5		6 teeth
6	2 teeth	No TeOnTo
7	3 teeth
8	4 teeth
9	5 teeth
10	6 teeth
11	4 TeOnTo	2 teeth
12		3 teeth
13		4 teeth
14		5 teeth
15		6 teeth
16	2 teeth	4 TeOnTo
17	3 teeth
18	5 teeth
19	6 teeth

Although 36 combinations were initially simulated,²¹ 19 representative cases are summarized in Table 4 to highlight the most significant performance trends.

These design modifications are analyzed using the three-dimensional finite element method (FEM) to assess their impact on the motor's characteristics and compare them with those of conventional SRM design. One significant advantage of the TeOnTo modifications is the shorter flux path compared to conventional structures. This shorter flux path results in a reduced magnetomotive force (MMF) drop and lower core losses, ultimately contributing to improved motor efficiency and performance.

As part of the study, the effect of varying the slot depth in the stator and rotor on torque generation was investigated. In the stator, increasing the slot depth by 10% led to a 40% improvement in torque. Further increasing the slot depth to 20% resulted in an additional 20% increase in torque. However, a further increase in slot depth to 30% resulted in only a 6% improvement in torque. Based on these findings, a 20% slot depth was determined to be the optimal choice for further analysis.

In the rotor, increasing the slot depth by 10% resulted in only a 4% improvement in torque. Increasing the slot depth to 20% caused a more substantial torque improvement of 36%, while a further increase to 30% only produced a 6% improvement. Therefore, a 20% slot depth was also chosen as the optimal value for the rotor in subsequent studies.

These findings highlight the significance of optimizing slot depth in both the stator and rotor to achieve substantial improvements in torque output. By selecting the optimal slot depth values (20% for both stator and rotor), the TeOnTo modifications enable enhanced motor performance, making them a promising approach for improving the efficiency and effectiveness of SRMs.

Simulation setup and assumptions

All modelling and simulation work in this study was carried out using Siemens Simcenter MAGNET. The baseline 6/4 SRM and all TeOnTo-modified configurations were modelled within the same environment to ensure consistency in performance comparison. The modelling and simulation procedure was as follows:

Geometry definition: The machine geometry was drawn directly in MAGNET according to the dimensions listed in Table 3. For each TeOnTo configuration, the tooth count and slot depth were modified while keeping the stack length, airgap, and winding arrangement unchanged.

Material assignment: The stator and rotor cores were assigned non-oriented silicon steel (from the MAGNET material library) with the associated B–H characteristics. Copper:

5.77e7 Seimens/meter was used for the phase windings.

Circuit excitation: A three-phase excitation circuit was constructed in the MAGNET environment. Phase currents were applied according to the intended energization sequence for the 6/4 SRM, with identical excitation conditions used across all models.

Simulation type: Static torque simulations were performed over a range of rotor positions to obtain torque–position characteristics. Transient simulations were carried out to determine peak torque, average torque, and acceleration under no-load conditions. The transient torque behavior was investigated through a time-domain finite element simulation using Siemens Simcenter MAGNET. For each SRM model, a constant, rated current was supplied from the start of the simulation. This continuous excitation, with no current switching or interruption, allowed for the measurement of the machine's inherent, or natural, transient response during the first electrical cycle. The resulting torque waveforms are valuable indicators of the starting torque and acceleration potential because they reveal the initial flux buildup and torque evolution.

Performance metrics: For each configuration, torque, average torque, acceleration, peak current, speed, and maximum flux density were extracted directly from the MAGNET simulation results.

Consistency of conditions: No changes were made to mesh settings, solver parameters, or analysis options between different configurations. All performance variations are therefore attributed solely to the geometric changes introduced by the TeOnTo modifications.

This setup ensured that each design variant was evaluated under identical modelling and excitation conditions, enabling a fair comparison of their torque, acceleration, and flux density characteristics.

The present study prioritized peak/average torque, acceleration, and weight reduction. Although instantaneous torque was recorded for verification, systematic torque-ripple optimization was not an objective of this design phase. Consequently, ripple metrics are not reported here. Torque smoothness considerations section discusses qualitative implications and mitigation options.

Theoretical linkage between tooth geometry and torque development

As outlined in Equations (2) and (3) in the Introduction, the torque per unit volume is directly proportional to ∂B/∂θ, the rate of change of flux density with respect to rotor position. In the TeOnTo configurations, the reduced tooth-face area increases local flux density B, which in turn increases ∂B/∂θ during the positive torque-producing interval. This theoretical relationship is clearly reflected in the FEA results: for example, the 18/16 configuration exhibits a 23% higher peak flux density at the aligned position compared to the baseline, translating into a corresponding increase in torque per unit volume.

Results and analysis

Teeth on Tooth (TeOnTo) design modifications are proposed in this paper by remodeling the stator, rotor, or both components of the switched reluctance motor (SRM). Each TeOnTo modification is unique and demonstrates distinct performance characteristics. The combinations of these TeOnTo modifications, as presented in Table 4, were created for the purpose of analyzing and identifying the optimum configuration that maximizes torque generation and overall motor efficiency.

The approach begins with the stator tooth kept unmodified, while the number of teeth on the rotor (TeOnTo) is increased from 2 to 6. Similarly, in another configuration, the rotor teeth are left unmodified, and TeOnTo modifications are introduced on the stator. In both scenarios, the 4-TeOnTo modification has shown the most notable torque improvement across all models tested.

To narrow down the analysis further, the study focuses on expanding the 4-TeOnTo modification in both the stator and rotor. In this analysis, the stator remains fixed with 4 teeth per pole, while the number of teeth on the rotor is varied from 2 to 6. Likewise, the vice versa configuration is also tested. Out of all the modification designs listed in Table 4, a selection of the most promising designs is illustrated in Figure 4. These designs reflect the effect of introducing additional teeth on both the stator and rotor. The number of poles in each modified model increases due to the introduction of smaller teeth on the rotor and stator. For clarity, the models are numbered based on the number of poles and the number of small teeth on each pole. This naming convention helps in distinguishing between various configurations and allows for easy identification of the number of poles and teeth in each model.

Figure 4.

Teeth on teeth modifications. (a) 4 stator TeOnTo (b) 4 rotor TeOnTo (c) 4 stator 5 rotor TeOnTo (d) 3 stator 4 rotor TeOnTo.

Each modification and its corresponding performance metrics, including torque generation and efficiency, are compared and analyzed in the following sections. These comparisons provide a comprehensive understanding of how different TeOnTo modifications impact the motor's overall performance, with the goal of identifying the most optimal configuration for enhancing the torque and efficiency of the SRM for EV applications.

Stator TeOnTo and no TeOnTo rotor

The stator Teeth on Tooth (TeOnTo) modification involves altering the stator teeth configuration, which directly influences the number of poles and consequently affects the torque and overall performance of the switched reluctance motor (SRM). For instance, if each stator pole has 3 teeth, the model is designated as a 12/4 configuration (i.e., 12 stator poles, 4 rotor poles). Similarly, the 18/4 model would have 3 teeth per stator pole and 4 rotor poles, leading to a total of 18 stator poles. This naming convention applies across all stator TeOnTo models, with the number of teeth on the stator teeth determining the number of virtual poles formed.

Performance comparison of stator TeOnTo modifications

The 12/4 model draws a high transient current of 18.31 A, similar to the “no TeOnTo” model. However, as the number of stator teeth increases, the current drawn by the coil decreases. This trend indicates that the stator TeOnTo modifications not only improve torque but also enhance the motor's efficiency by reducing the current required for operation.

Table 5 presents the performance comparison of the various stator TeOnTo models. Key observations from this comparison include:

12/4 Model: As shown in Figure 5, the 12/4 configuration produces the least torque, with the transient current being relatively high compared to the other models. The low torque makes it unsuitable for high-performance applications where high starting torque is crucial.

18/4 Model: This model demonstrates a 14% improvement in torque over the 12/4 configuration, highlighting the advantage of modifying stator teeth. However, its torque is still lower than that of the 24/4 model, suggesting that the 18/4 configuration is a stepping stone to better performance.

24/4 Model: The 24/4 model emerges as the optimal stator TeOnTo modification, generating the highest peak torque and acceleration. The peak torque of 45.49 Nm is 90.2% higher than the torque generated by the “no TeOnTo” model. This model provides significantly improved performance, especially in terms of starting torque, compared to the 12/4 model. The oscillating nature of the torque in the 24/4 model (due to the presence of multiple teeth per pole) is a typical feature of SRMs with TeOnTo modifications, but it still produces superior torque.

36/4 Model: While the 36/4 model reaches a higher speed than the 12/4 model, it produces less torque and acceleration, highlighting the diminishing returns of increasing the number of stator teeth beyond the optimal 4 teeth per pole.

Figure 5.

Transient torque characteristics of SRMs with various stator TeOnTo configurations under rated current excitation (continuous supply applied from simulation start).

Table 5.

Performance comparison of stator TeOnTo models

Model	Torque (Nm)	Average Torque (Nm)	Current (A)	Speed (rpm)	Acceleration (rad/s ² )
12/4	38.74	10.91662	18.31	568.3	7216
18/4	44.13	11.66267	16.7	605	8220
24/4	45.49	11.96855	17.21	626.5	8474
30/4	41.00	11.97458	17.72	626	7636
36/4	36.38	11.80164	15.49	612.5	6776

This indicates that after an optimal number of stator teeth (around 4 in this case), any additional teeth lead to diminishing returns in terms of torque production due to core saturation and increased magnetomotive force (MMF) losses.

In Figure 6, the torque generated by the 24/4 model is compared to that produced by the “no TeOnTo” model. As shown, the 24/4 model produces nearly double the torque of the “no TeOnTo” model. The torque in the 24/4 model is oscillating, which is typical of SRM designs with multiple teeth on the stator. The uniform torque produced by the “no TeOnTo” model contrasts sharply with the fluctuating torque in the TeOnTo models. Despite these oscillations, the 24/4 model offers significantly better performance in terms of torque and starting capabilities.

Figure 6.

Comparison of transient torque response between the 24/4 TeOnTo model and the baseline SRM (no TeOnTo) configuration.

Figure 7 illustrates the flux density variations across different stator TeOnTo models. The “no TeOnTo” model has a maximum flux density of 2.12 T. As the number of teeth on the stator increases, the flux density increases as well. For instance, the 18/4 model results in a maximum flux density of 2.156 T, and the 24/4 model further increases the flux density to 2.162 T. This increase in flux density contributes to higher torque generation. However, beyond a certain point (such as in the 36/4 model), the core material begins to saturate, and the torque production decreases as a result.

Figure 7.

Flux density plots for all stator TeOnTo models.

The Stator TeOnTo modifications, particularly the 24/4 model, significantly enhance the torque and acceleration capabilities of the switched reluctance motor. The 24/4 model produces 90.2% more torque than the “no TeOnTo” model, with a substantial increase in starting torque. Although increasing the number of stator teeth improves performance up to a point, further increases beyond 4 teeth per pole lead to saturation, reducing the effectiveness of the modifications. Therefore, in this section, the 24/4 TeOnTo configuration is identified as the optimal choice, offering the best balance of torque, acceleration, and current efficiency.

Rotor TeOnTo and no TeOnTo stator

The rotor Teeth on Tooth (TeOnTo) modification models are essentially the inverse of the stator TeOnTo models. Instead of modifying the stator teeth, the rotor teeth are altered, which leads to variations in the number of virtual poles formed by the rotor. For instance, if the rotor poles have 3 teeth, and the stator remains unmodified, the model is named as the 6/12 model. In the case of a 6/20 model, the rotor poles would have 5 teeth each, creating 20 virtual poles, while the stator poles remain unchanged. The naming convention for these models follows the same logic, with the number of rotor teeth affecting the number of virtual poles.

Performance comparison of rotor TeOnTo modifications

Table 6 presents the detailed performance comparison of the rotor TeOnTo modifications. From this, the following insights can be derived:

6/8 Model: As illustrated in Figure 8, this model generates very low torque compared to all other rotor TeOnTo modifications. The current drawn by the coil during the transient period is also relatively high, indicating inefficiency. The 6/8 model does not provide sufficient torque for practical applications.

6/16 Model: This model delivers the highest maximum transient torque of 43.11 Nm, which is 80.2% higher than the torque produced by the “no TeOnTo” model. The performance of the 6/16 model is notably superior in terms of torque and acceleration. Although the maximum transient torque is higher for the 6/16 model, it is worth noting that the flux density during peak current remains relatively low, which contributes to better efficiency. This model consistently produces peak torque and acceleration, indicating that the optimal rotor TeOnTo modification lies around 4 teeth per pole on the rotor.

6/20 and 6/24 Models: While these models show slight improvements in average torque, they do not generate higher peak torque or acceleration compared to the 6/16 model. Additionally, the increase in rotor TeOnTo beyond 4 teeth causes a reduction in maximum torque, likely due to the saturation of the core material. These models also experience slightly higher current draw during the transient phase compared to the 6/16 model.

Figure 8.

Transient torque characteristics of SRMs with various rotor TeOnTo configurations under continuous rated current excitation.

Table 6.

Performance comparison of rotor TeOnTo models

Model	Torque (Nm)	Average Torque (Nm)	Current (A)	Speed (rpm)	Acceleration (rad/s ² )
6/8	34.47	9.671353	19.88	569	7156
6/12	42.48	10.33448	17.44	606.3	9036
6/16	43.11	10.59051	16.87	633.8	9267
6/20	41.46	10.72925	15.26	653.5	8965
6/24	38.01	10.81602	15.39	663.7	8252

The current drawn during the transient period is also a critical factor in evaluating motor performance. The 6/8 model draws high transient current, while the current drawn decreases as the number of rotor TeOnTo teeth increases. The 6/16 model, in particular, strikes a good balance between high torque production and lower current draw, making it more efficient than the 6/8 and 6/20 models.

To better visualize the differences in torque generation, Figure 9 compares the torque produced by the 6/16 model with the “no TeOnTo” model. As depicted in the Figure 9, the 6/16 model produces nearly double the torque of the “no TeOnTo” model. While the torque produced by the “no TeOnTo” model is relatively uniform throughout the operation, the torque in the 6/16 model oscillates, corresponding to the number of TeOnTo teeth on the rotor.

Figure 9.

Comparison of transient torque response between the 6/16 TeOnTo model and the baseline SRM, highlighting torque buildup behavior during the first electrical cycle.

This oscillating behavior is typical of SRM designs with TeOnTo modifications and should be carefully managed to optimize motor performance.

Figure 10 presents flux density plots for various rotor TeOnTo models. The “no TeOnTo” model has a maximum flux density of 2.12 T. As rotor TeOnTo is introduced, the flux density gradually increases. For example, with 2 teeth on each rotor pole (6/12 model), the maximum flux density increases to 2.2583 T, and with 5 teeth per rotor pole (6/20 model), the flux density increases to 2.544 T. While higher flux densities are beneficial for torque production, they can also lead to core saturation, especially when rotor TeOnTo configurations exceed 4 teeth. The increased saturation due to excessive rotor teeth reduces the motor's overall efficiency, which is why the 6/16 model offers the best performance balance.

Figure 10.

Flux density plots for all rotor TeOnTo models.

The rotor TeOnTo modifications, particularly the 6/16 configuration, show the most promising results in terms of torque, acceleration, and efficiency. Increasing the number of rotor teeth improves torque up to a certain point (i.e., 6/16 model) but can lead to negative effects, such as core saturation and higher current draw, as the number of rotor teeth increases beyond 4. Therefore, the 6/16 model is identified as the optimal configuration in terms of maximizing torque and acceleration, while maintaining efficient current draw and flux density.

Stator TeOnTo and rotor TeOnTo

In the analysis of the Teeth on Tooth (TeOnTo) design modifications, a total of 36 possible combinations were explored. Among these, the models with 4 TeOnTo modifications on both the stator and rotor emerged as the best performers, demonstrating higher peak torque and acceleration compared to the other models. Additionally, the current drawn by these optimized configurations was found to be lower than that of the “no TeOnTo” model, showcasing the effectiveness of the modifications in improving efficiency. To narrow down the search for the optimal design, further exploration was conducted with the 24/4 and 6/16 models.

Performance comparison of stator 4 TeOnTo with rotor TeOnTo modifications

Table 7 presents the performance comparison of the stator 4 TeOnTo model with varying rotor TeOnTo configurations.

Table 7.

Performance comparison of stator fixed TeOnTe and varied rotor TeOnTo models

Model	Torque (Nm)	Average Torque (Nm)	Current (A)	Speed (rpm)	Acceleration (rad/s ² )
24/8	43.5	11.05912	24.7	614	9034
24/12	46.52	11.34701	22.08	677.3	9888
24/16	67.39	12.95148	20.48	739.2	14,485
24/20	68.16	13.1493	20.52	736.8	14,739
24/24	53.54	11.91341	20.15	726.6	11,623

Key findings from this comparison are as follows:

24/8 Model: This configuration resulted in the lowest performance across all combinations, with lower torque, speed, and acceleration compared to the other models. The transient current drawn by the 24/8 model was also higher than the no TeOnTo model, making it less efficient. The peak torque produced by the 24/8 model was considerably lower than the other configurations.

24/20 Model: The 24/20 model demonstrated significantly improved performance, producing higher torque and acceleration than the 24/8 model. Although the speed of the 24/20 model was almost identical to that of the 24/16 model, the torque produced by the 24/20 model was much higher. Specifically, the 24/20 model generated a peak torque of 68.16 Nm, which is 184.9% higher than that of the no TeOnTo model. Furthermore, the current drawn by the 24/20 model during the transient phase was significantly lower than that of the 24/8 model.

As the rotor TeOnTo increased beyond 24/20, the peak torque slightly decreased. This observation highlights the diminishing returns of increasing the number of rotor teeth beyond a certain point, with 24/20 being one of the optimal configurations for maximizing peak torque (presented in Figure 11). Additionally, increasing rotor TeOnTo gradually decreases the current drawn by the coil, improving the overall efficiency of the motor.

Figure 11.

Comparative transient torque profiles of the 24/20 TeOnTo configuration and the baseline SRM, showing torque enhancement due to increased rotor tooth segmentation.

Performance comparison of stator TeOnTo modifications with rotor 4 TeOnTo

Table 8 presents the performance comparison of various stator TeOnTo models with a fixed rotor TeOnTo of four teeth. The findings from this comparison reveal distinct patterns in the performance of different configurations:

36/16 Model: This model exhibited the lowest torque and acceleration among the stator TeOnTo models with rotor 4 TeOnTo. The increase in number of stator teeth to 36 reduced the overall effectiveness of the machine.

12/16 Model: This configuration resulted in lower speed and higher transient current, making it less desirable in terms of both performance and efficiency.

18/16 Model: The 18/16 model demonstrated the best performance in terms of torque, speed, and acceleration. Its acceleration was particularly notable, significantly outperforming models like 30/16 and 36/16.

Table 8.

Performance comparison of rotor fixed TeOnTe and varied stator TeOnTo models

Model	Torque (Nm)	Average Torque (Nm)	Peak Current (A)	Speed (rpm)	Acceleration (rad/s ² )
12/16	59.9	11.06361	21.24	3999	12,875
18/16	72.43	12.20018	22.96	4201	15,570
24/16	67.39	12.95148	20.48	4435	14,485
30/16	45.46	11.62752	19.65	4222	9772
36/16	43.66	11.32193	19.05	4112	9385

The 12/16 model showed higher acceleration than the 30/16 and 36/16 models, despite producing less overall torque. This suggests that acceleration performance is influenced by the optimal balance between the number of stator teeth and the overall motor configuration.

Figure 12 illustrates the starting torque produced by the best performing model 18/16 and the no TeOnTo model. The 18/6 model demonstrated a peak torque that was 3 to 4 times higher than that produced by the no TeOnTo model, showcasing the significant improvement in starting torque due to the TeOnTo modifications. This improvement is crucial for applications where high starting torque is necessary, such as in electric vehicle propulsion systems.

Figure 12.

Comparative transient torque profiles of the 18/16 TeOnTo configuration and the baseline SRM, illustrating improved peak torque and acceleration performance during initial excitation.

An analysis of the transient torque waveforms shown in Figures 5, 6, 8, 9, 11 and 12 reveals the machine's initial operating characteristics under continuous excitation. These plots detail the torque buildup during rotor alignment, providing both the maximum torque developed during flux buildup and the effective average torque under steady conditions. The transient responses derived from these figures are essential for evaluating the starting torque and acceleration capabilities of the proposed designs.

Figure 13 presents the flux density patterns for the 24/20 and 18/16 TeOnTo models. It is evident that increasing the number of teeth on both the stator and rotor results in a considerable increase in flux density. The higher flux density through the teeth of the motor core leads to increased torque and acceleration, as the machine is able to generate more electromagnetic force. This increase in flux density contributes to the improved performance observed in the TeOnTo modified models.

Figure 13.

Flux density plots for 24/20 and 18/16 TeOnTo models.

Steady-state torque characteristics

Each SRM design was simulated for 60 ms under continuous rated-current excitation to measure the torque response. Initially, from 0 to 24 ms, the torque built up as the magnetic field formed, a period characterized by fluctuating “transient torque”. Following this, from 25 to 60 ms, the torque reached a stable, repeating “quasi–steady-state operation”. The torque waveform of the top-performing 18/16 TeOnTo model during its steady-state period (31–60 ms) is shown in Figure 14. It confirms that the motor achieved a stable magnetic alignment and produced periodic torque with less fluctuation than during startup.

Figure 14.

Steady-state torque waveform of the 18/16 TeOnTo SRM model (31–60 ms region) showing periodic torque behavior after flux stabilization.

The average torque figures in performance comparison Table 8, however, represent the 30-ms simulation, capturing the motor's performance during both its initial transient phase and its later, more stable, continuous operation. This comprehensive evaluation provides a more realistic assessment of the SRM's torque capabilities under rated conditions.

Magnetic saturation effects

A notable consequence of the TeOnTo modifications is the increase in local flux density within the stator and rotor teeth, as observed in the flux density plots of Figures 7, 10 and 13. While this concentration of magnetic flux is the primary driver for the observed torque enhancement, it also introduces the risk of magnetic saturation, particularly when the number of teeth per pole exceeds the optimal range. For example, the baseline “no TeOnTo” configuration exhibits a maximum flux density of approximately 2.12 T, whereas the optimal 24/4 and 6/16 configurations increase this to 2.162 T and 2.258 T, respectively. In contrast, over-modified designs, such as the 36/4 or 6/20 configurations, reach flux density levels exceeding 2.50 T, approaching the knee of the lamination steel B–H curve, where incremental permeability drops sharply.

Once saturation is initiated in the tooth tips or back iron, the motor's ability to further increase torque with additional teeth diminishes, as evidenced by the torque reduction beyond four teeth per pole in both stator and rotor modifications. This saturation effect accounts for the point at which performance gains level off and, in some cases, begin to decline in models with an excessively high number of teeth per pole. Therefore, while increasing tooth count is beneficial up to a point, careful consideration of material saturation limits is essential to balance torque enhancement with efficiency and long-term reliability.

Summary of design modifications

In summary, the TeOnTo design modifications offer significant improvements in both torque and efficiency when compared with the baseline 6/4 SRM. Among the tested configurations, models with four TeOnTo segments on both stator and rotor poles consistently delivered superior performance in peak torque, acceleration, and current efficiency. The 24/20 model achieved the highest peak torque and efficiency, while the 18/16 model showed notable improvements in starting torque.

By systematically optimising the number of teeth on the stator and rotor, substantial gains in performance (higher torque output, faster acceleration, and reduced current draw) can be realised. These improvements stem from increased flux concentration in the narrowed tooth tips, which raises torque per unit volume. However, the data also show that excessive segmentation can approach material saturation, at which point further gains are limited or performance may decline. Table 9 summarises the performance of the highest-performing configurations identified in this study. Of the numerous combinations analysed, two models, 18/16 and 24/20 consistently ranked highest across multiple performance metrics.

Table 9.

Performance comparison of all best performing models

Model	Torque (Nm)	Average Torque (Nm)	Current (A)	Speed (rpm)	Acceleration (rad/s ² )
24/4	45.49	11.96855	17.21	626.5	8474
6/16	43.11	10.59051	16.87	633.8	9267
24/20	68.16	13.1493	20.52	736.8	14,739
18/16	72.43	12.200018	22.96	700.2	15,570

Peak torque and acceleration

18/16 delivered the highest peak torque (72.43 Nm), a 68% increase over the 6/16 model and a 203% improvement compared to the baseline 6/4 SRM. This model also achieved the highest acceleration, making it the most effective configuration for torque-demanding applications.

24/20 offered slightly lower peak torque than 18/16 but delivered higher average torque and speed, making it attractive for applications requiring a balance between peak and continuous performance.

Flux density and torque per unit volume

Increased flux density is the primary driver for torque-per-volume improvement. In the 18/16 model, the reduced pole area created by the TeOnTo slots concentrated magnetic flux in narrower regions, increasing local flux density. However, this also brought the material closer to its saturation limit, highlighting the trade-off between torque gains and potential saturation effects.

Steady-State performance

Under steady-state no-load conditions, the 18/16 model operated within a speed range of 550–700 rpm. This indicates good versatility for applications with varying speed demands, although load-dependent speed variations will require further investigation.

General trends and limitations

Across all tested configurations, performance improvements from additional teeth followed a similar pattern:

Moderate segmentation increased torque per unit volume by shortening the flux path and improving magnetic loading.

Excessive segmentation led to early saturation, producing a plateau or decline in torque. These trends are expected to hold for other SRM designs with similar lamination materials, airgap dimensions, and excitation levels. However, the exact optimal tooth count and slot depth are case-specific and depend on pole count, lamination steel properties, and operating current.

The absence of experimental validation is a current limitation; future work will include prototype fabrication and testing to verify these simulation-based findings under practical load conditions.

Weight reduction on providing TeOnTo

The weight of an electrical machine plays a significant role in its overall performance, efficiency, and cost-effectiveness. When designing motors for applications such as electric vehicles (EVs), industrial machines, and various other systems, minimizing the weight without sacrificing performance is a key factor. The Teeth on Tooth (TeOnTo) modifications not only improve the torque and efficiency of switched reluctance motors (SRMs), but they also result in a substantial reduction in the motor's overall weight. This weight reduction, in turn, contributes to lowering the cost of raw materials required for manufacturing, making the motor more cost-effective.

The TeOnTo modifications induce changes in the geometry of the rotor and stator, which leads to better performance and a reduction in the amount of material used in the motor. Table 10 presents the weight reduction achieved in various TeOnTo models, highlighting the benefits of these modifications.

6/8 model: This model has the smallest reduction in weight, with a 362 g decrease compared to the baseline design.

36/16 model: At the other end of the spectrum, this model achieves a maximum weight reduction of 1.124 kg, showing that significant material savings can be achieved with larger modifications to the teeth structure.

18/16 model: This model, which delivers the best performance in terms of torque and acceleration, reduces the motor weight by 1.044 kg, bringing the total motor weight down to 22.576 kg. This reduction is particularly advantageous for applications where the weight of the motor directly impacts the overall system performance.

Table 10.

Weight reduction on various TeOnTe models

Weight of no TeOnTo model is 23.62 kg
Model	Weight (kg)	Model	Weight (kg)
12/4	23.138	24/8	22.638
18/4	23.042	24/12	22.565
24/4	23	24/16	22.534
30/4	22.978	24/20	22.517
36/4	22.962	24/24	22.506
6/8	23.258	12/16	22.672
6/12	23.185	18/16	22.576
6/16	23.153	24/16	22.534
6/20	23.137	30/16	22.512
6/24	23.126	36/16	22.496

Benefits of weight reduction

In addition to cost savings and improved performance, reducing the weight of the SRM can also have practical implications for the design and operation of systems in which the motor is used:

Improved Efficiency: A lighter motor requires less energy to operate, which is especially important in applications where energy consumption is a concern, such as in battery-operated vehicles. The reduction in weight leads to lower energy losses, making the motor more efficient and extending battery life in electric vehicles.

Better thermal management: A lighter motor may also offer improved thermal performance, as reduced weight may reduce the overall thermal mass of the system, allowing for quicker heat dissipation

Enhanced Mobility: In mobile applications, where the motor is integrated into a vehicle or portable device, every kilogram saved directly contributes to overall vehicle performance. For example, in electric vehicles, lighter motors reduce the overall weight of the vehicle, which in turn improves fuel efficiency or driving range.

Faster Acceleration and Better Handling: In systems where fast response times are critical, such as in robotics or high-performance electric vehicles, a lighter motor can improve acceleration and control. This is because the system's overall inertia is reduced, allowing for quicker reactions and better handling.

Comparative position of TeOnTo Among SRM design strategies

The simulation results show that the TeOnTo topology occupies a distinct performance niche among SRM design methods. While split-tooth stators¹ and multiple-tooth poles³ can increase torque, their benefits plateau or reverse once saturation occurs. Rotor skewing and pole-bridging^6,7,12 effectively mitigate noise but offer limited torque gains. Hybrid excitation¹⁴ improves efficiency but requires additional materials and magnets, increasing cost. In contrast, TeOnTo delivers up to 68% torque improvement (18/16 model) with a weight reduction exceeding 1 kg, without introducing permanent magnets or major structural complexity. These combined benefits make it well suited for EV and high-torque industrial drives where both torque density and cost-efficiency are priorities.

Torque smoothness considerations (qualitative)

The TeOnTo topology concentrates flux in narrower tooth faces to raise torque per unit volume. A practical consequence is that local permeance changes with rotor position can be more abrupt than in the baseline 6/4 model. This study focused primarily on maximizing torque density rather than minimizing torque ripple. Preliminary inspection of instantaneous torque traces shows more pronounced oscillations in some TeOnTo variants, which is consistent with the literature on split/slotted teeth and segmented structures.^1–3^,6–8 The observed ripple increase is expected for flux-concentrating designs, but the substantial torque gains, particularly the 203% improvement in the 18/16 configuration proved a strong foundation for subsequent ripple optimization work.

In applications where smoothness is secondary to launch/starting capability (e.g., industrial traction, agricultural machinery), the observed trade-off can be acceptable, particularly given the measured gains in peak/average torque and weight reduction. For applications with tighter NVH constraints, several established measures can be applied on top of TeOnTo without altering its basic geometry: pole-tip shaping,⁸ stator pole bridges,⁶ skewed or semi-skewed rotors,^12,13 and control-level current profiling/dwell optimization.^24,25 Integrating these measures in a co-design loop is expected to attenuate ripple while preserving most of the torque gains and is left for future work.

Conclusion

This paper has presented a novel Teeth-on-Tooth (TeOnTo) redesign of the switched reluctance motor (SRM), specifically targeting applications that demand high torque density and cost efficiency, such as electric mobility and traction drives. By introducing additional small teeth on the stator and rotor poles, the flux path is reshaped and concentrated, resulting in improved torque per unit volume and better utilization of magnetic material. Through systematic finite element analysis of 36 stator–rotor combinations, the influence of tooth count and slot depth was quantified in terms of torque, acceleration, efficiency, and flux saturation.

The results demonstrate that the TeOnTo approach consistently outperforms conventional SRMs, with the 18/16 configuration emerging as the most effective design. This model achieved the highest peak torque and acceleration while also providing a weight reduction of over 1 kg compared to baseline designs, offering both performance and economic advantages. The findings indicate that the proposed modifications can deliver superior torque output without requiring major changes to winding configuration or manufacturing complexity, thereby preserving the inherent simplicity and reliability of SRMs.

Overall, the TeOnTo concept represents a practical and scalable enhancement to SRM design. It provides an attractive balance of torque improvement, material efficiency, and robustness, making it suitable for electric vehicles, agricultural machinery, and industrial traction systems where high torque density and durability are essential.

Limitations and future work

While the proposed TeOnTo configurations clearly enhance torque and acceleration, this study did not conduct a detailed evaluation of torque ripple. Preliminary observations suggest that although the average torque is increased, the modified tooth structure can introduce higher-frequency ripple components compared to the smoother torque of conventional SRMs. A full quantitative ripple analysis, along with vibration and acoustic characterization, will be required to confirm the trade-offs between torque improvement and dynamic smoothness.

This work concentrated on torque enhancement rather than torque smoothness. While the TeOnTo modifications successfully increased peak and average torque, some configurations may exhibit higher ripple content compared to the baseline design. This trade-off is typical of designs that concentrate magnetic flux to improve torque density. The significant performance gains achieved (up to 203% peak torque increase) justify investigating ripple mitigation techniques in future work without compromising the core torque improvements.

Future work will therefore focus on:

Extending the analysis to include torque ripple and noise performance under different load conditions.

Optimizing tooth geometry further to balance torque gain with ripple minimization.

Investigating thermal performance and efficiency under real operating cycles, including EV duty profiles.

Validating the proposed designs experimentally through prototype fabrication and hardware testing.

By addressing these aspects, the TeOnTo approach can be further refined into a well-rounded SRM solution that not only improves torque density and weight efficiency but also meets the stringent requirements of modern electric drives.

The simulation-based nature of this study reflects a common approach in current SRM research, where finite element analysis provides the foundation for design optimization.²⁶ While experimental validation remains essential for confirming these results, the systematic methodology employed here follows established practices in the field and provides a solid foundation for subsequent prototype development and testing.

Footnotes

ORCID iD

Vijayaragavan CM

Funding

The authors received no financial support for the research, authorship, and/or publication of this article.

Declaration of conflicting interests

The authors declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.

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