Design, optimization, and prototyping of a 2 kW BLDC motor (48 V, 3,000 rpm, 12 poles/36 slots) for light electric vehicle applications, with the objective of reducing torque ripple from 18% to below 6%, while limiting the reduction in average torque to no more than 10% and achieving an efficiency of ≥85%.
Simultaneous optimization of three parameters—magnet geometry, skew angle, and winding configuration—without an undesirable reduction in torque; accurate FEM simulation of harmonic interactions; fabrication of skewed magnets and distributed windings using advanced equipment; and precise measurement of instantaneous torque ripple during dynamometer testing.
Systematic literature review, analytical design, 2D modeling in ANSYS Maxwell, optimization using the Taguchi method (27 simulations for three variables at three levels) and sensitivity analysis, prototype fabrication, experimental testing (Back-EMF, resistance, inductance, and torque measurement using a 5 kW dynamometer), and validation against simulation results.
FEM models of the baseline and optimized motor designs, complete CAD drawings, an assembled prototype, test reports and validation curves, a manufacturing process manual, and design documentation for transfer to production.
Jey Oil Refining Company
Design and development of magnetoactive nanoceramic coatings to inhibit the nucleation and growth of coke deposits in process equipment used in bitumen-producing refineries. Through surface engineering, these coatings prevent the initial adhesion of coke, thereby enhancing equipment efficiency and extending its service life.
Jey Oil Refining Company
Design and manufacture of an industrial turbo-compressor to supply combustion chamber air and plant compressed air by utilizing the heat generated from the combustion of excess gas. The key innovation is the elimination of the power turbine rotor and the splitting of the hot gas flow upstream of the gas-generator turbine inlet, which reduces costs while increasing aerodynamic loading.
Jey Oil Refining Company
Design and fabrication of a compact heat exchanger for preheating the compressed air supplied to the oxidation reactor from 90°C to 200°C, using direct flame heat and combustion products from excess gas. The heat exchanger is installed in the excess-gas burner wall and fabricated from A516 steel plate with minimized welding requirements.