WHAT?
Woodward currently uses an expensive, outsourced distributed winding DC motor to operate its gas control values and electric linear actuators.
Primary Objectives
Replace distributed winding with concentrated winding
Reduce material and manufacturing costs
Maximize torque output and maintain external geometry profile
HOW?
Used Finite Element Method Magnetostatic (FEMM) to design and validate motor geometry
Generated 3D Solidworks models and 2D drawings of each critical component
Implemented GD&T and tolerance stack-up analysis to ensure proper fit and alignment in final assembly
Coordinated with independent suppliers for part procurement
RESULTS
12 Slot/10 Pole single-layer configuration
Maintained critical dimensions (ID & OD) to allow for easy installation
Stator geometry optimized to maximize torque and minimize saturation
Custom 3D printed insertable bobbins designed to simplify installation & removal