1. Understanding Applications
Design of electric motor starts with understanding application. We can approach to features once requirements is determined. for ex. i am giving example of motor requirements for electric car.
- High efficiency (for longer mileage)
- Wide speed range
- High specific power (Starting torque must b higher for smoother experience)
- Low rotor inertia (easy to start and stop)
- Economic (Affordability)
- less maintainance (Longer life cycle)
- Harsh enviroment
2. Basic design choice
After selection of requirements, choose basic design configuration and topology and materials according to application point of view.
Motor configuration
- Radial flux
- Axial flux
- Transverse flux
Motor topology
- DC
- Induction
- BLDC (Brushless dc)
- PMSM (Permanent magnet synchronous motor)
- SRM (Switch reluctance motor)
Material
- Grade of materials used
Cooling of motor
- Air cooled
- Liquid cooled
- Natural convection
Electromagnetic design
- By using analytical quations
- Available data
Choosing dimensions on basis of electromagnetic equations and data
- Volume of rotor
- No of slots/poles
Thermal Analysis
- CAE Softwares
Mechanical design
- Shaft and casing
- Bearing selection on basis of loading
- Thermal analysis and heat dissipation
Now, Our analysis is complete, If we get desired results than move to prototyping and testing phase, and if we didn’t get expected results than move back to starting phase and iterate process.
Prototyping
Testing
- Designing test rigs (Application of mimicing of operating enviroment)
- Design validation plan
-
Analysis of results
- Report will be passed to manfacturing team