This paper proposes an extended set of variables for numerical optimizations of tooth-coil permanent magnet synchronousmachines. The design variables for the extended set are chosen based on the magnetic asymmetries introduced by the saturatedcore under the loading conditions. The extended set allows to reach considerably higher values of torque density and significantreduction of torque ripple in comparison with a conventional set of optimization variables. The conventional and extended setsare compared on an example of a FEM simulation of a double-layer winding SPM-rotor TC-PMSM. Considerably better optimalmachine is obtained when the extended set of variables is utilized. The paper showcases the design and optimization of electricalmachines using only free and open-source softwar
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