A Comprehensive Design, Analysis and Fabrication of a Brushless Permanent Magnet Motor for UAV Applications

This paper presents a detailed study on the design, analysis, and fabrication of a brushless Permanent Magnet (PM) motor for unmanned aerial vehicle (UAV) applications. The study begins with the calculation of dimensions for a 2 kW outer rotor permanent magnet brushless PM motor using analytical electromagnetic sizing equations, followed by design and analysis in finite element analysis (FEA) software. The mechanical design of the motor includes the stator, rotor, casing and shaft designs, respectively. The mechanical stress analysis of the rotor structure is also performed to ensure its structural integrity during the operation. The fabrication process involves the manufacturing of key motor components, such as the rotor and stator, followed by assembly and testing. The no-load back-EMF and torque speed profile of the motor is obtained experimentally. This testing validates the motor’s performance and ensures that the designed parameters meet the required specifications for UAV applications.