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University of California, San Diego
Mechanical and Aerospace Engineering
MAE 156B: Senior Design Project
Project Description
Project Description
The project aims to develop a high-efficiency, lightweight coreless motor with a PCB-based stator for hybrid power systems in industrial drones. Key design efforts include optimizing rotor airflow to enhance cooling, running thermal simulations, and building a modular test bench for performance evaluation.
This project serves to validate and refine the motor's performance through iterative testing and analysis, contributing to the advancement of hybrid power technology for unmanned systems.
Background
Background
KickStage Consulting is a leading consulting firm based in Miramar, specializing in comprehensive manufacturing and supply chain management solutions. With expertise spanning from startups to multinational enterprises, KickStage provides technical project management, product development, and production optimization services.
This project is supported by LiftWorks, an innovative aerospace startup known for creating hybrid power systems tailored for unmanned aerial applications. Together, we are pushing the boundaries of engineering excellence and efficiency to meet the evolving demands of modern technology.
Objectives
Objectives
The goal of this project is to develop and test a high-efficiency, lightweight, and manufacturable coreless motor with a PCB-based stator. This design is intended to meet demanding current density requirements while incorporating advanced thermal management solutions to maximize performance. The motor will serve as both a generator and a starter for industrial drones. The outcome will be a hybrid power solution optimized for unmanned systems such as drones and UAVs.
Coreless Motor
Coreless Motor
Eliminates traditional iron core, using permanent magnets.
Lightweight and highly efficient.
Requires self-supporting windings and careful thermal management due to lack of a heat sink.
PCB-Based Stator
PCB-Based Stator
Replaces wire windings with PCB traces for precise geometry.
Compact, easy to manufacture, but limited winding spacing.
Requires robust thermal management due to higher temperatures.
Rotor Design
Rotor Design
Includes strategically placed holes to increase airflow across the stator surface.
Reduces overheating by enhancing cooling through blade and hole configurations.
Designed to improve thermal management without compromising performance.
Test bench
Test bench
Features an open-air design to maximize cooling and visibility.
Uses a BLDC motor to spin the shaft with bearing and mount blocks for stability.
Mounted on 8020 rails for flexibility and modularity in testing configurations.
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