Electrification is the future…
Infinite System Design, through the technical partnership with Drive System Design, has the capability to design, prototype and test motors in-house along with develop bespoke inverters to suit the motor.
Motor Design:
All industries are seeing a demand for higher efficiency, more power dense motors which is pushing the motor speed up and is a challenge for all motor designers to maintain cooling, durability and NVH to meet target requirements while reducing cost. Infinite System Design has experience successfully developing motors in both low and high voltage applications, low voltage motors to run actuators and high voltage motors to run vehicles. The motors are designed in MotorCAD where initial parameters can be fed from the SYSTEM OPTIMISATION process and then tuned in a detailed design phase to ensure target power/torque/speed requirements. To ensure thermal requirements are met, lumped parameter thermal models can be utilised through in-house software or more advanced particle based spray simulation and finite element thermal analysis can be used. Where NVH targets are key, FEA can be utilised to analyse frequency response.
Motor Design Capabilities:
- Electro-magnetic design
- Performance and cost optimization
- Motor prototyping and assembly
- Motor winding development trials and prototype production
- Motor testing and characterisation
- Thermal testing development of both oil & water cooling methods
Inverter Design:
The demand for more efficient electric machines also demands a more efficient inverter, bringing new technologies such as Silicon-Carbide. With this in mind, Infinite System Design has developed the capability to design and test inverters in-house.
Infinite System Design, through the technical partnership with Drive System Design, has the capability to develop motor inverters in-house including control system design and development, prototype controller and power electronic hardware design, thermal design and analysis, contorl software design and auto-coding, controller simulation and development and test rig tuning.
Case Study: Traction Motor Design and Prototyping
Our technical partners Drive System Design developed a traction motor for an electric vehicle from the ground up. Utilising MotorCAD the initial concepts were modelled to ensure they met key torque, power and speed targets while maximising efficiency at key operating points based on residency data from simulation models. The prototype motor was manufactured, assembled and tested in-house and met all design criteria. Having the entire process in-house, design through to test, streamlines the design process and reduces time and cost. Infinite System Design can support bespoke motor design projects in collaboration with Drive System Design.
Case Study: Motor Thermal Model
Our technical partners Drive System Design developed thermal models to understand the cooling requirements of a motor. Initially, a lumped parameter simulation model was created to model the temperature of the motor over a duty cycle. A further study utilised a combination of particle based fluid modelling and finite element thermal modelling to ensure the motor met the desired design criteria and sized the cooling system for the motor. Testing various cooling methods allows the customer weigh-up system complexity/cost with design requirements.