Design Process

The Design Process

While each project is unique, SDT aims to follow an established design process, incorporting six key stages for projects requiring prototyping:

1. Develop a specification
2. Produce an outline design
3. Produce a full, optimised, design
4. Create drawings and documentation
5. Build a prototype
6. Test and evaluate the prototype

Design Process

Develop a specification

Typically designers will develop a motor which is simply a variation of an existing product. SDT, however, usually designs machines from scratch and often for unusual tasks, so it's necessary to consider every aspect of the design from a very early stage by producing a full specification.

The specification will include speed, power and technical standards, but should also include less obvious parameters such as the required production quantity, mounting arrangements, torque-speed-efficiency maps, and clearly defined voltages, currents and duty cycles.

Careful wording is essential to ensure that nothing is overlooked by the designer, leaving the customer completely satisfied with the outcome

Design Process

Produce an outline design

When the specification has been written and agreed by all parties, SDT will produce an outline design. This will indicate the expected final performance of the finished design and reveal any problem areas.

The outline design is an important stage in a product's development as, after subsequent reviews and modifications, it may determine the specified machine's feasibility.

Design Process

Produce a full, optimised, design

This stage of the process advances the outline into a full, verified, design, using finite element analysis and thermal modelling techniques. Further work may be carried out to explore specific issues, such as UMP (unbalanced magnetic pull), tolerancing or cogging.

SDT utilises its proprietary automated stochastic vector optimisation software to advance its designs rapidly and efficiently.

This is followed by a manual assessment of the results, using graphs and trend charts, to achieve the optimised design. It can then be checked against the original specification, reviewed and re-tested using different methods if necessary.

Design Process

Create drawings and documentation

Following the client's approval of a design, detailed drawings and documentation can be completed.
Sophisticated management tools help control the design process, ensuring that appropriate documentation is provided at each stage

Design Process

Build a prototype

While each project is unique, EMX aims to follow an established design process, incorporting six key stages for projects requiring prototyping:

EMX has built up a network of skilled contractors which manufacture all the necessary components and assemblies for a prototype machine.

We can manage these specialists, checking each part as it becomes available, ensuring that this stage of the process meets operational, timescale and budget objectives.

Design Process

Test and evaluate the prototype

For our prototype testing, SDT uses a wide range of specialist instruments and power electronic drives.

Our performance tests include the measurement of torque-speed-efficiency, cogging torque and thermal behaviour.

When the testing and evaluation stage has been completed, a detailed report, documenting methods as well as results, can be presented to the client.

Product realisation- Performance is fully tested at the application level under actual
costs are weighed against volume requirements and schedule to complete the program implementation.

For many years, SDT has worked with both motor manufacturers & OEM companies and, as a result, has an enviable track record of successful design and development projects.