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