Motor Design Engineer

Motor Design & Architecture – Design and develop high-power, high-voltage BLDC/PMSM motors for propulsion and actuation applications, defining architecture based on voltage, power, torque, speed, efficiency, duty cycle, mass, cooling and environmental requirements.

Motor Sizing & Trade-offs – Perform motor sizing and design trade-offs for torque density, power density, efficiency, thermal performance, mechanical integrity and operating-speed requirements.

Electromagnetic Design – Perform electromagnetic design and analysis covering back EMF, torque, torque ripple, cogging torque, losses, efficiency, flux density, demagnetization margin and short-circuit behaviour using ANSYS Maxwell, Motor-CAD, JMAG, Flux or equivalent.

Motor Mechanical Design – Design rotor, shaft, stator housing, end shields, bearings, retaining systems, cooling jackets and mounting components, considering structural integrity, manufacturability, assembly and inspection requirements.

Rotor Dynamics & High-Speed Design – Perform rotor dynamic analysis including critical speeds, shaft deflection, bearing loads, balancing, stability, rotor integrity, overspeed margins and magnet retention for high-speed operation.

Materials & Manufacturing – Select and evaluate electrical steels, permanent magnets, copper conductors, structural materials, insulation, adhesives and retaining materials based on strength, temperature, magnetic properties, density and environmental requirements; support suppliers and manufacturing teams.

Thermal Design – Analyse copper, iron, magnet and mechanical losses; develop air/liquid cooling concepts, cooling jackets and thermal paths; determine component temperature limits and validate thermal models against experimental results.

High-Voltage Insulation – Develop motor insulation systems covering phase-to-phase, phase-to-ground, slot, turn-to-turn and terminal insulation, including creepage, clearance, dielectric strength and PWM/high dV/dt considerations.

Motor Dynamics & Vibration – Analyse vibration, resonance, balancing and frequency-domain behaviour across the operating speed range; correlate rotor-dynamics/FEA predictions with experimental results and investigate abnormal vibration or noise.

Testing & Qualification – Develop and execute motor-level testing covering no-load/load performance, efficiency mapping, torque-speed, temperature rise, continuous/peak power, high-speed, overspeed, vibration, shock, thermal cycling and HV insulation testing.

Data Analysis & Failure Investigation – Analyse test data against simulations and design predictions, identify failure modes, perform root-cause analysis and support qualification reports and technical documentation.

System Integration – Work with motor-drive/inverter, battery, cooling and propulsion teams to define electrical, mechanical, thermal and control interfaces and support closed-loop, transient, fault, system-level and field/vehicle testing.

3–4 years of hands-on experience in electric motor design, development or testing.

Strong understanding of PMSM/BLDC motor fundamentals.

Experience with high-speed or high-power motor development is preferred.

Strong knowledge of electromagnetic, mechanical and thermal aspects of motor design.

Experience with motor simulation/FEA tools such as ANSYS Maxwell, Motor-CAD, JMAG, ANSYS Mechanical, or equivalent.

Good understanding of rotor dynamics and high-speed rotating machinery.

Experience with shaft, bearing, rotor and housing design.

Good knowledge of engineering materials and material selection.

Understanding of electrical insulation systems for high-voltage motors.

Experience with motor testing, instrumentation and data analysis.

Ability to perform engineering calculations independently and correlate simulations with experimental results.

Willingness to work extended hours as required.