Design and Material Optimization of BLDC Motor Windings using FEM for Motor-Pump Applications using Existing Stator Stamping

This paper covers the design of a 1 Hp, 48 V brushless DC (BLDC) motor-pump utilizing an existing V4 stator stamping. The conceptual BLDC motor design is simulated by choosing different winding configuration and material options, where the number of turns also changed. An analytical approach specifically suited to pumping applications is proposed. Detailed scrutiny of the BLDC motor is carried out based on Finite Element Method (FEM) incorporating sustainable design practices. Simulations of magnetic flux distribution in Infolytica MagNet 7.1 are executed to determine the output characteristics. BLDC motors at 48 V corresponds to an efficiency of 94.06% produced power is 745 W. Torque maximum and speeds corresponded at 7.16 Nm and 3000 rpm whereas cogging torque is 0.74 Nm. The motor's efficiency and stable speed improve overall conversion efficiency by 6% in operational limits, confirming the proposed BLDC motor-pump is energy efficiency.