High-Efficiency BLDC Rotor Optimization

My existing washing-machine drive uses a 12-slot, 8-pole, spoke-type BLDC rotor that already meets torque and acoustic targets, yet there is still headroom to raise overall efficiency. The goal of this project is to redesign the rotor, model the gains in finite-element analysis, and then confirm the improvements on a physical prototype.

Scope of work
• Refine the current rotor geometry, materials, or magnet arrangement to minimize copper + core losses and push the efficiency curve upward across the normal speed range (≈ 500–1 500 rpm).
• Run full 2-D/3-D FEA: back-EMF, flux distribution, cogging, torque ripple, loss breakdown, and temperature sensitivity. Ansoft Maxwell, JMAG, Motor-CAD or an equivalent professional toolset is acceptable.
• Deliver an updated CAD package (STEP/DXF) and manufacturing drawings ready for laser-cut lamination stacking and magnet insertion.
• Build and instrument one prototype rotor (or work with my local shop) and conduct dynamometer tests that reproduce the simulated duty points. I need raw data and an analysed report that directly compares baseline vs. improved design.

Acceptance criteria
1. At least a 3 % absolute efficiency increase at the duty point of 400 W mechanical output and 1 000 rpm, confirmed by both simulation and test.
2. No degradation in peak torque, acoustic noise, or thermal rise versus the current rotor.
3. Complete documentation package: design files, simulation models, test procedures, and signed-off results.

I will supply the baseline CAD files, material spec sheet, and prior FEA reports after award. Collaborate openly on design iterations; brief weekly updates are plenty.