Turnless BLDC Motor
Turnless BLDC Motor
2019-2020
I consulted a local business to build a turnless BLDC motor. The motor utilizes turnless inductors with high current to produce a high power density. I designed the mechanical structure for the BLDC motor. This included designing the stators for the motor, permanent magnet rotors, and the bearings and support structure. I performed a stress analysis on the motor rotors to avoid large deflections, the motor stator to avoid dynamic warping, and the structure. Performed a tolerance analysis on various parts to ensure they met preset specifications.
Additionally, I designed a microchannel water cooler to extract the heat from power electronics. I simulated the heat transfer of the power electronics to ensure proper heat transfer. I specified the flow rate requirements of the pump needed to remove the heat from the system. I designed a modular, high power inverter system to control the BLDC motor.
Skills/Tools used:
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3D CAD using Solidworks
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Stress simulation using Solidworks
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Fluid heat transfer simulation using Solidworks
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2D drawings for manufacturing
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Tolerance analysis
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RFQ
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DFM utilizing: CNC, EDM, water cutting, and 2D/3D lathe
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Technical presentations
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System Design
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BOM generation
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Mechanism design
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Prototyping techniques