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Designing and analyzing electrical motors is a highly complex engineering task requiring the integration of electromagnetic, thermal, structural, material science, and control-system disciplines. If you are looking for professional services in electrical motor design and analysis, you are at the right engineering consulting firm for developing new motors or upgrading existing designs to achieve higher efficiency, reliability, and performance. We design and develop electrical machines in 1-phase, 2-phase, 3-phase, 4-phase, and even advanced 5-phase and 6-phase architectures for specialized applications requiring:
★ Higher torque density ★ Fault tolerance and redundancy ★ Reduced torque rippl ★ Smoother operation and lower vibrationWe provide comprehensive design, modeling, simulation, and optimization services to ensure continuous, reliable, and efficient operation of electrical and electronic drive systems. Our capabilities cover static, low-frequency, transient and high-frequency electromagnetic simulations, along with:
★ Core loss and copper loss estimation ★ Efficiency mapping ★ Torque ripple and cogging torque reduction ★ Thermal management and cooling strategy design ★ Vibration and acoustic noise predictionOur team consists of specialists in electrical machine design, power electronics, control strategies, and multiphysics FEA/CFD simulation. Based on client requirements, we carry out:
✔ Electromagnetic sizing
✔ Winding and slot design
✔ Magnetic circuit analysis
✔ Material selection
✔ Controller and drive-system integration
For motor families including:
✔ Induction motors (single-phase & three-phase)
✔ Synchronous motors
✔ Brushless DC (BLDC) motors
✔ Permanent Magnet Synchronous Motors (PMSM)
✔ Switched Reluctance Motors (SRM)
✔ Universal motors
✔ Stepper motors (PM, VR, Hybrid)
Technical strengths include:
★ Microstepping from full-step to ultra-fine microstep control ★ 0.25° and below step resolution ★ Closed-loop stepper systems with encoder/resolver feedback ★ Hybrid stepper topology optimizationElectromagnetic FEA for:
★ Flux density distribution ★ Detent torque and holding torque ★ Dynamic torque characteristics ★ Thermal and structural robustness for harsh environments ★ Torque ripple minimization and acoustic noise reductionWe also co-develop controllers and drives, including:
★ Constant-current chopper drivers ★ PWM and vector drive schemes ★ Multi-phase current sharing and balancing ★ Stall and position-loss detection ★ EMI/EMC-compliant electronicsWe support your journey from concept to prototype and validation, including:
★ Complete electromagnetic design ★ Stator and rotor geometry development ★ Winding pattern and slot-fill optimization ★ Integration with gear trains, linear stages or actuators ★ Prototype fabrication support ★ Testing, qualification and documentation✔ Perform electromagnetic analysis to optimize the motor design for efficiency, torque, and power factor
✔ Conduct thermal analysis to ensure the motor can dissipate heat effectively
✔ Determine appropriate cooling methods (e.g., convection, forced air) and design cooling systems
✔ Design the mechanical components of the motor, including the rotor, stator, and housing
✔ Consider materials, manufacturing processes, and mechanical tolerances
✔ Integrate control systems and electronics for motor speed and torque control
✔ Build prototypes of the motor for testing and validation
✔ Perform various tests, including performance testing, efficiency measurements, and reliability testing
✔ Optimize the motor design to achieve high efficiency and minimize energy losses
✔ Prepare detailed documentation, including design specifications, drawings, and test reports
Custom Motor Design: Tailoring motor designs to specific requirements, such as torque, speed, and size constraints.
Electromagnetic Design: Analyzing magnetic fields, flux distribution, and electromagnetic forces within the motor.
Thermal Analysis: Assessing heat generation and dissipation to ensure the motor operates within temperature limits.
Finite Element Analysis (FEA): Using FEA for detailed structural and thermal analysis of motor components.
Computational Fluid Dynamics (CFD): Analyzing airflow and heat transfer to optimize motor cooling.
Electromagnetic Field Analysis: Studying the motor's magnetic field for performance optimization.
Optimization: Iterative design processes to optimize motor performance, efficiency, and reliability.
Efficiency Analysis: Evaluating and improving the motor's efficiency for energy savings.
Prototype Development: Assisting in the fabrication and testing of physical motor prototypes.
Testing and Validation: Conducting various tests to validate the motor's performance and adherence to specifications.
Computer-Aided Design (CAD): Creating detailed 3D models of motor components.
Simulation: Simulating motor behavior under different operating conditions.
Ensuring that the designed motors comply with industry standards and regulations.
Providing comprehensive documentation on motor design, analysis results, and recommendations. Offering clear reports on performance characteristics, efficiency, and any design improvements.
Collaborating with our team for any specific project requirements and goals. We offering expert advice on motor selection, customization, and integration into larger systems.
