![]() Finally, we picked Neodymium magnets due to their higher magnetic flux.We are really thankful to our manufacturing partners who believed in Tresa. A lot of big manufacturers turned us down, especially for the stator lamination production, it was too unique, and not something that gets used in radial flux motors. ZetWerks was also used for a few of the components, but direct vendor relations were important, so they were prioritized. Peenya and Rajajinagar became the hot spots for us to go and get our job done. Fortunately, Bangalore has some of the best precision manufacturers in the country, thanks to ISRO, other automobile companies and Bosch/Crompton/ABB, etc! A lot of work from them gets outsourced to private vendors.Parallely, we kept looking for manufacturing partners and got a few amazing ones! We also spent a lot of time making a few parts in-house on our own CNC machine. Our team built the whole motor in Ansys, and all the simulations put together would have taken some 60 days of computing! Several design parameters like power target (defining inner and outer radius), number of turns, copper coil diameter, width between any two magnets, stamping size, the total number of CRGO steel plates in the stator lamination stack, basic cooling system, etc were tested before arriving at the final configuration. Simulate, simulate, and simulate! Since we had to commit to a design, and making a motor is a major investment, we spent a good 11-12 odd months on simulations and research (more so because ANSYS, or any other simulation software cannot be used for simulating the topology specific to our motor, finally we had to write our own macros to link 100+ dependent and independent parameters between Maxwell and MATLAB to get the simulations up and running).Where do we get the CRGO steel plates (we needed ~0.2mm thick plates) and how do we make a motor stamping out of it? How will we stack some 100 of them on top of each other and hold them in place?īreaking down the problems helps solve them in a structured manner.How do we get the copper coils on the stator? Since this is a new topology, there are no manufacturers that would have ready-made setups!.How do we actually install the magnets on the rotor? Without a solid mechanism, magnets just wouldn’t stay at their desired locations. ![]() This means we need extremely high magnetic fields.
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