Motor Design Engineer BLDC, PMSM, SynRM (R&D)

VANA VENKATA VIGNESH NAIDU

Motor Design Engineer – BLDC — PMSM — SynRM

Bangalore, India +91-918******* *****************@*****.*** linkedin.com/in/venkata-vignesh PROFILE SUMMARY

Electrical Motor Design Engineer with hands-on experience in the design and electromagnetic analysis of BLDC, PMSM, and Synchronous Reluctance Motors. Proficient in ANSYS Maxwell and ANSYS Motor-CAD for motor sizing, performance evaluation, and design validation. Currently working as an R&D Intern at IFB Industries, con- tributing to appliance motor development through simulation, optimization, and performance analysis. TECHNICAL SKILLS

• Motor Types: BLDC (Inner & Outer Rotor), PMSM, Synchronous Reluctance Motor (SynRM)

• Electromagnetic Design: Slot–Pole Selection, Flux Barrier Design, Back-EMF Optimization, Torque Ripple Re- duction

• Analysis: Flux Density, Torque-Speed Characteristics, Iron & Copper Losses, Efficiency Calculation

• Simulation Tools: ANSYS Motor-CAD, ANSYS Maxwell 2D/3D

• Documentation & Presentation Tools: Microsoft Excel, Microsoft PowerPoint PROFESSIONAL EXPERIENCE

Research & Development Intern – Electric Motor Division IFB Industries Pvt. Ltd., Bangalore June 2025 – Present

• Involved in the design and electromagnetic analysis of BLDC, PMSM, and SynRM motors for home appliance applications.

• Performed FEA simulations to evaluate torque, efficiency, back-EMF, flux distribution, and iron losses.

• Supported design optimization studies to reduce torque ripple and improve overall motor performance.

• Assisted in correlating simulation results with experimental test data for design validation. PROJECTS

BLDC Spoke-Type Motor – Washing Machine Application

• The objective of this project was to design a high-torque, low-speed BLDC motor suitable for washing machine agitation and spin cycles, with focus on efficiency, robustness, and appliance duty requirements.

• A 12-slot, 8-pole spoke-type rotor topology was selected to improve flux concentration and torque density com- pared to conventional surface-mounted BLDC motor designs.

• Detailed electromagnetic simulations were carried out in ANSYS Maxwell to analyze flux density distribution, back-EMF waveform quality, average torque, and torque ripple.

• Iron losses and electromagnetic performance were evaluated across operating conditions to ensure suitability for continuous and intermittent appliance operation.

• The proposed design was compared against conventional BLDC motors to demonstrate improvements in torque density and overall efficiency.

• Prototype fabrication support and experimental performance testing were carried out to validate the simulation results.

BLDC Outer Rotor Blower Motor (BPMOR) – Appliance / HVAC Application

• Designed an outer-rotor BLDC motor intended for blower and HVAC applications, where low acoustic noise, smooth torque, and compact mechanical structure are critical performance requirements. 1

• A 12-slot, 10-pole configuration was adopted to achieve smoother electromagnetic torque production and reduced cogging effects at higher operating speeds.

• The motor was rated for 200 W output power at 3600 RPM with a rated torque of 0.6 Nm, suitable for continuous blower operation.

• Comprehensive electromagnetic simulations were performed using ANSYS Motor-CAD, with detailed field-level FEA validation carried out in ANSYS Maxwell, to study flux distribution, back-EMF characteristics, torque behav- ior, and individual loss components.

• Through electromagnetic optimization, an overall efficiency of approximately 85% was achieved.

• A key achievement of this design was limiting torque ripple to only 0.8%, enabling smooth, low-vibration, and low-noise operation.

Synchronous Reluctance Motor (SynRM) – Appliance Drive

• This project focused on the design of a magnet-free Synchronous Reluctance Motor as a cost-effective and sustain- able alternative for appliance drive systems.

• Rotor geometry with multiple flux barriers was designed to maximize the saliency ratio and enhance reluctance torque production.

• Electromagnetic analysis was performed in ANSYS Maxwell to study flux paths, torque ripple, back-EMF charac- teristics, phase current waveforms, and flux density distribution.

• Motor performance was evaluated in terms of torque capability and efficiency, highlighting advantages over induc- tion motors for appliance applications.

• The design demonstrated benefits such as reduced material cost, improved reliability, and elimination of rare-earth magnets.

Permanent Magnet Synchronous Motor (PMSM)

• Designed and analyzed a high-performance 9 kW Permanent Magnet Synchronous Motor intended for applica- tions requiring high efficiency and torque density.

• The motor was designed to operate at a rated speed of 4908 RPM, with emphasis on achieving a wide constant- torque operating region.

• Electromagnetic simulations were conducted to obtain torque–speed characteristics, efficiency maps, and detailed electromagnetic loss distribution.

• A peak torque of 17 Nm was achieved with approximately 95% efficiency under simulated operating conditions.

• The PMSM design was evaluated for electromagnetic and thermal robustness across the operating range. EDUCATION

Bachelor of Technology – Electrical & Electronics Engineering SRKR Engineering College, Bhimavaram, Andhra Pradesh CGPA: 7.81 / 10 2021 – 2025

LEADERSHIP & ACTIVITIES

• IEEE Chairperson – SRKR Engineering College Student Branch

• Senior Member – Association of Electrical Engineers

• Coordinated technical workshops, seminars, and student activities LANGUAGES

English (Professional), Telugu (Native), Hindi (Beginner) 2

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