PAST
PUBLISHABLE
PROJECTS

A showcase of our people's capabilities from past projects they have worked on in their careers.

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PAST PROJECT 1: MOTOR DESIGN
USING FEA

The electric vehicle industry is rapidly evolving, necessitating improvements in the design of electric motors, particularly in the realms of power magnetic devices (PMDs). The challenge lies in enhancing motor designs to reduce system losses, mass, volume, and cost, while simultaneously increasing power capability, reliability, and ease of large-scale manufacturing. Addressing this involves a complex multi-physics problem that includes mechanical, electrical, and thermal elements.

Our Solution:
• Utilized COMSOL Multiphysics® software to develop optimized electric motor designs with high power density.
• Adopted a modular approach to electric vehicle design that allows for flexibility in motor and battery configurations.
• Designed magnetic components that balanced volume and power loss constraints using advanced optimization algorithms and a 2D electromagnetic field analysis.
• Investigated the complex effect of nonlinearity of steel on high-frequency conductor losses and thermal behavior to prevent motor failures.
• Leveraged the power of COMSOL's Application Exchange for collaborative problem-solving and knowledge sharing.

The Results:
• Successfully developed innovative, efficient, and high power density electric motor designs, creating performance at the forefront of the electric vehicle industry.
• The modular approach enhanced flexibility in motor and battery configurations, ensuring optimal vehicle performance across a range of scenarios.
• Efficiently optimized magnetic components, striking a balance between minimizing power loss and maintaining compact size.
• Comprehensive investigation of steel nonlinearity provided valuable insights into conductor losses, significantly enhancing motor reliability and preventing potential failures.
• Project breakthroughs published in IEEE's Spectrum Magazine.

PAST PROJECT 2: FULLY INTEGRATED AND CUSTOM LEV POWERTRAIN SYSTEM DESIGN

The project is intended to address several key challenges in the design of Light Electric Vehicle (LEV) powertrain systems. Size and performance requirements dictated that the powertrain needed a fully integrated and custom designed BMS, battery pack, inverter, charger, and powertrain controller. Sophisticated user interface and system control was also required to meet a user-friendly design.

Our Solution:
• Developed a comprehensive proof-of-concept for a 3.6 kW LEV powertrain.
• Implemented a high-efficiency dual BLDC motor drive architecture.
• Designed and integrated a li-ion battery management system (BMS).
• Embedded a powertrain controller in an on-board microcontroller.
• Designed PCB prototype for electronics integration, and used additive manufacturing for motor mounts and gears.
• Created a user-friendly USB-C compatible charger and a Bluetooth 4.0 user controller.

The Results:
• Successfully delivered a highly efficient, and user-friendly LEV powertrain system.
• Significantly extended battery lifespan with custom BMS solution compared to COTS alternatives.
• Seamlessly integrated BMS, inverter, charger, powertrain controller, and Bluetooth module into the powertrain system, demonstrating exceptional prowess in design and integration.
• Rigorously validated all custom solution design requirements from component-level up to system-level.

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