Electric Motor Design Engineer EV & Defense Applications

PROFESSIONAL EXPERIENCE

PROFESSIONAL SUMMARY

MANOJ G

Mobile:+91-938******* E-Mail:********************@*****.*** LinkedIn: https://www.linkedin.com/in/manoj-gurumoorthy-783b5821a Electric Machine Design Engineer with 2+ years of experience in BLDC and PMSM development for EV, defense, UAV, and industrial applications. Specialized in Motor-CAD–based electromagnetic and thermal design of radial and axial-flux machines, including high-speed and traction motors. Proven in optimizing torque–speed performance, efficiency, and manufacturability, with strong understanding of inverter constraints, MTPA, and field-weakening regions for production- ready R&D designs.

Junior Electromagnetics Engineer – Machine Design

Vinuruk Technologies, Coimbatore, Tamil Nadu Nov 2024 – Present

• Lead electromagnetic and thermal design of BLDC and PMSM machines across radial and axial-flux topologies for EV, defense, UAV, and specialized industrial applications using Ansys Motor-CAD.

• Design high-speed and traction motors with focus on torque density, efficiency, and compact integration, meeting application-specific performance envelopes.

• Define DC bus voltage, current limits, and speed ranges to generate torque–speed characteristics, efficiency maps, and thermal limits under realistic inverter constraints.

• Analyze base speed, voltage-limited regions, and high-speed operating boundaries through Motor-CAD drive frameworks, ensuring the motor envelope matches application duty cycles.

• Perform iterative motor optimization based on simulation and test feedback, improving losses, thermal margins, magnet utilization, and manufacturability.

• Support design-freeze activities by preparing motor performance data, simulation summaries, and validation documentation from concept through prototype readiness.

• Resolve cross-functional engineering queries related to magnetic circuits, material selection, cooling strategies, and production feasibility.

• Conduct feasibility and concept-to-design studies for customer-specific motor requirements, evaluating electromagnetic, thermal, and packaging constraints in Motor-CAD and delivering validated motor architectures following technical reviews and client approvals.

• Mentor interns and junior engineers on motor fundamentals, EM modeling, and R&D workflows. Projects & Key achievements:

• High-Speed Motor – Defense (51,000 RPM, 3.5 kW): Designed a high-speed PMSM ensuring electromagnetic stability, rotor integrity, and thermal reliability under extreme dynamic and environmental conditions.

• UAV / Drone Motors:

Engineered lightweight BLDC motors with optimized power-to-weight ratio and thermal behavior, improving endurance and operational reliability.

• Axial-Flux Traction Motor (63 kW, 5,500 RPM):

Developed an axial-flux PMSM for Aerospace application. Re-engineered from rare-earth to ferrite magnets under supply constraints, maintaining efficiency and performance through magnetic circuit and thermal optimization.

• Ferrite-Based & Assisted Motor Platforms:

Designed ferrite-assisted radial-flux and synchronous machines for EV applications, achieving performance comparable to rare-earth designs through advanced EM and thermal tuning. PROFESSIONAL SKILL SET

• EESM Study (Learning):

Performed end-to-end electromagnetic and thermal design of a 1.2 kW Electrically Excited Synchronous Motor

(EESM) in Motor-CAD as a learning and capability-building project, covering topology selection, magnetic circuit development, loss estimation, and thermal feasibility assessment. Assistant Engineer – Electrical Design – PDT

Texmo Industries, Coimbatore, Tamil Nadu Jan 2024 – June 2024

• Executed type testing of newly developed and upgraded motor products in compliance with IEC standards, supporting performance enhancement and release readiness.

• I analyzed test data to identify design gaps and recommend targeted improvements in efficiency, thermal behavior, and reliability.

• Performed competitive benchmarking of motors and pump sets, generating technical insights to guide product upgrades and new development.

• Conducted teardown analysis of benchmark products to understand electromagnetic design choices, materials, and construction practices.

• Investigated field failures by correlating operating conditions with performance deviations, contributing to root- cause analysis and reliability improvement.

• Evaluated synchronous reluctance motors (SYNRM) across multiple drive platforms, supporting motor–drive compatibility and optimization efforts.

Graduate Engineering Trainee (GET)

Texmo Industries, Tamil Nadu Dec 2021 – Oct 2023

• Completed structured rotation across testing, compliance, and product engineering, gaining end-to-end exposure to industrial motor development.

• Performed type testing, monobloc motors and submersible pump sets in accordance with ISI standards, supporting certification and market release.

• Assisted in product selection for ISI certification by identifying mismatches between declared specifications and measured performance.

• Supported live product testing and validation, bridging design intent with operating behavior.

• Built strong foundations in motor testing, standards compliance, and manufacturing-oriented engineering practices.

Core Motor Design

• BLDC & PMSM Design (Radial & Axial Flux)

• Electromagnetic Design & Optimization

• Thermal Analysis & Cooling Concepts (Air / Liquid Cooled)

• Torque–Speed & Efficiency Mapping

• High-Speed & Traction Motor Development

• Magnetic Circuit Design & Loss Analysis

• Motor Feasibility Studies & Concept Development

• Motor Testing, Benchmarking & Validation (IEC / ISI) Drive & Control Awareness

• Inverter Current & Voltage Constraints

• Base Speed & Voltage-Limited Operation

• MTPA & Field-Weakening Regions

• Motor–Drive Compatibility Understanding

ACHIEVEMENTS & EXTRACURRICULAR

DECLARATION

ACADEMIC DETAILS

Tools & Software

• Ansys Motor-CAD (EM & Thermal)

• Siemens Motor-Solve

• Motor XP

• Microsoft Excel (Engineering Calculations & Data Analysis)

• MS Office (Technical Documentation)

Professional Strengths

• Technical Documentation & Design Reporting

• Cross-Functional Collaboration

• Customer-Oriented Feasibility Analysis

• Mentoring & Knowledge Sharing

• Bachelor of Engineering (B.E.) – Electrical and Electronics Engineering Sri Ramakrishna Engineering College, Coimbatore

2019-2023

• Higher Secondary Certificate (HSC)

The Lakshmi Mills Higher Secondary School, Kovilpatti 2018 – 2019

• Secondary School Leaving Certificate (SSLC)

The Lakshmi Mills Higher Secondary School, Kovilpatti 2016 – 2017

Leadership & Activities

• Secretary, Electrical & Electronics Technical Association (EETA), 2022-2023

-Led the technical events & knowledge sharing activities, strengthening peer collaboration and leadership within the department.

• NCC Army Wing Cadet – ‘A’ ‘B’ ‘C’ Certificates

-Built discipline, resilience, and leadership through structured training and team-based operations.

• NSS Volunteer

-Contributed to community programs, demonstrating teamwork and social responsibility. Achievements

• Finalist – Smart India Hackathon (SIH), 2022

• Selected for Senior Inter-District Hockey Tournament, Coimbatore District, 2025

• Participant – Hockey India Junior Academy National Championship, 2021

• Organized Departmental Technical Symposium as EETA Secretary, 2023 I am G Manoj do hereby declare that all the above furnished information is true to the best of my knowledge & belief. MANOJ G

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