Senior Electrical Design Engineer Motor Innovation and EMC Design

ABHIJIT WALSE (Senior Engineer-Motor Design)

Samata Colony, Majalgaon · Phone-842*******

********.*****@*****.*** · linkedin.com/in/abhijit-walse-807b941a0 Committed Electrical Design Engineer with proven track record in delivering challenging design of rotating machine and development projects for Commercial and defence applications. Adept at designing Electric Motor using analytical and FEA design tools. Presently working as Senior motor design engineer, leading the development of submersible IPMSM, Switched Reluctance Motors (SRM) and Synchronous Reluctance Motors

(SynRM) as part of new technology innovation initiatives. SKILLS

Good knowledge of IS (Indian Standard), IEC (International Electrotechnical Commission) & NEMA standard used for rotating electric machines.

Experienced in Finite Element Analysis (FEM) for Electromagnetic devices on FEM / FEA platforms like Ansys Maxwell (2D/3D) & JMAG-Designer 22.0 (FEA and Thermal).

Excellent skills in MATLAB & MS Excel for creating analytical calculators and documentations.

Good Knowledge of various Testing, Validation & Benchmarking methods for electric motor.

Experienced at prototyping and reverse engineering of motors.

Experienced in working on effective implementation of Cross Functional Team in problem solving. EXPERIENCE

1) Ecozen Solutions Privet Limited, Pune (From April 2024 to till date) SENIOR ENGINEER MOTOR DESIGN

Designed a series of Interior Permanent Magnet Synchronous Motors (IPMSMs)

- Designed motors for submersible water pump application, covering 3HP, 5HP, 7.5HP, and 10HP in a V4 frame size.

- Successfully achieved the targeted efficiency in all developed prototypes. Delivered 1–2.5% higher efficiency compared to market-available motors of the same size.

- Optimized electromagnetic design, resulting in 18% to 20% reduction in active material costs compared to market-available motors, without compromising performance.

- Working on design of surface IMPSM water pump motors, aiming to replicate the efficiency gains and cost reductions achieved in the submersible motor series. Designed High-Efficiency Switched Reluctance Synchronous Motor (SRM)

- Designed a general-purpose 132M frame, 10HP, 1500 RPM SRM, achieving IE4 efficiency of 92.6%— 2.6% higher than benchmark Chinese motor, with 20% reduction in active material cost.

- Achieved this performance with a 35% shorter core length compared to a benchmark Chinese SRM motor.

- Currently developing an IE5 efficiency variant of SRM targeting equal or lower cost than Magnet based IMPSM motor with the goal of improved sustainability and supply chain resilience.

- Designed a 132M frame, 3HP, 3600 RPM SRM for surface pump application, achieving efficiency of 86% equal to benchmark IPMSM motor, with 15% reduction in active material cost. Designed High-Efficiency PM assisted Synchronous Reluctance Motor (PM-SynRM)

- Designed 3HP 3000 RPM permanent magnet assisted submersible synchronous reluctance motor for water pump application, in a V4 frame size.

- Successfully achieved the targeted efficiency of 81%, equal to benchmark IPMSM motor, with 13% reduction in active material cost compared to my designed IPMSM motor.

- Achieved 0.83 power factor at rated operating condition in design. 2) Pranshu Electricals Pvt Ltd. Aurangabad (From Aug 2021 to Mar 2024) ELECTRICAL DESIGN ENGINEER

Design of induction, PMDC, BLDC motors.

- Designed premium-efficiency IE3/IE4 3-Phase Induction Motors (ACIM) across 63 to 280 frame sizes.

- Designed low-noise motors for submarine applications and EMI/EMC-compliant, torpedo shock-proof induction motors for the Indian Navy.

- Developed a BLDC motor with only 2% cogging torque for gimbal systems in aviation applications.

- Expert in designing frameless BLDC torque motors for compact, high-torque applications—eliminating the need for gearboxes.

PROJECT DEVELOPMENT

Reverse engineering of PMDC & FWDC motors for Defence applications

- Reverse engineered PMDC and FWDC motors, including:

• Azimuth angle control PMDC motor for the Pinaka missile launcher.

• FWDC motor for hydraulic pump drive in T-90 tank.

- Got experience of designing critical components e.g., strip winding, compact tacho generators, complex brush holder assemblies and achieving good thermal stability in motor replicating same performance.

- Proficient in developing custom test setups and Acceptance Test Procedures (ATPs) tailored to specific operational environments and application needs.

- Prototypes of this motor are successfully validated and accepted by Indian defence agencies. The Motors are now serving Indian defence.

EDUCATION

DEGREE IN ELECTRICAL ENGINEERING, Y.C.C.E. NAGPUR. (AUG 2018-JUN 2021) Have technical, numerical and economic skill oriented degree in electrical engineering with 7.8 CGPA. DIPLOMA IN ELECTRICAL ENGINEERING, GOVT. POLYTECHNIC PUNE. ( AUG 2015-JUN 2018) Have technical and management skill oriented diploma in electrical engineering with 82.20%. SUMMARY

Over the past 4.5 years as an Electrical Design Engineer, I have evolved myself as a motor design solution provider progressing from theoretical knowledge to practical application, and from technical execution to innovative design creation.

Working in competitive industry, has developed my ability to design cost optimized, high performance motor solutions without compromising on quality or efficiency. With hands-on experience in designing a wide range of rotating electrical machines, I consider myself an enterprising and versatile engineering professional, skilled in delivering low-cost, high-efficiency motor designs across both commercial and defence sectors.

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