[02]
2025
Project
[Design]
Assembled Thermal Solution
Illustrative concept to demonstrate methods; parameters are intentionally generic. Any resemblance to real designs is coincidental. Content policy: T&Cs.
[02]
2025
Project
[Design]
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Thermal model and Validation
Illustrative concept to demonstrate methods; parameters are intentionally generic. Any resemblance to real designs is coincidental. Content policy: T&Cs.
[02]
2025
Project
[Design]
Assembled System Structural Integrity
Illustrative concept to demonstrate methods; parameters are intentionally generic. Any resemblance to real designs is coincidental. Content policy: T&Cs.
Electro-Mechanical System Design for NPD
[02]
2025
Project
[Design]
Range of Visal Facets and Variations of Project.
Illustrative concept to demonstrate methods; parameters are intentionally generic. Any resemblance to real designs is coincidental. Content policy: T&Cs.
System Design & Development of a High-Power Electro-Mechanical System
This project entailed the design and development of a high-power electro-mechanical system with nominal operating parameters exceeding 800V and 300A. A critical design requirement was the assurance of robust thermal and structural integrity under severe operational conditions, including high-flow liquid cooling and significant multi-axis vibration loads. The system was also engineered to meet stringent compliance standards for the railway and aerospace industries.
Working Details
Architecture & P&ID Development: Mission profiles were distilled into a detailed process‑and‑instrumentation diagram for the ~40 bar coolant loop and ~840 V DC‑link, embedding safety interlocks and DFMEA‑driven redundancy.
Busbar Innovation: A laminated Cu‑Al busbar managed high current; coupled thermo‑mechanical FEA predicted <0.1 mm expansion and ≤48 MPa stress, eliminating fatigue risk.
Thermal Solution: Motor‑CAD and CFD sized a 5.6 K W⁻¹ cold plate with graphite paste TIM, holding core temperatures below 63 °C at 95 % load with a 14.2 L min⁻¹ cooling flow, all packaged within a compact 120 mm envelope.
Structural Robustness: Modal and harmonic analyses placed the first natural frequency at 290 Hz, safely above the operating vibration spectrum that peaks at ~3.7 g in three axes.
Control & Co‑Simulation: ANSYS–Simulink co‑simulation achieved a current slew rate ≤2 ms and <1 % THD, confirming dynamic performance.
Verification & Compliance: Laboratory testing to DO‑160G and EN 50155 demonstrated temperature and deflection within ±8 % of predictions, completing the certification dossier.
Tools and Skillset
Motor-CAD
ANSYS Maxwell & Electronics Suite (Icepak, Mechanical)
Simulink / MATLAB; AutoCAD Plant 3D (P&ID)
Transient & steady-state CFD/FEA
DFMEA; Compliance engineering (DO-160G, EN 50155);
Modal & harmonic analysis
Test-plan development; Python data-acquisition scripting.
