Winch Motor Product Development
Migrate from Brushed DC to BLDC
Extended Torque Speed Range
Current winch technology is inefficient. Winches are designed using brushed permanent magnet DC motors, and the system efficiency can be as low as 15% with current draw as high as 320 amps at full rated load. Switching to a properly rated BLDC motor could greatly improve the performance of the winch within acceptable cost parameters.
Continuous Solutions utilized an in-house electric machine design optimization toolbox to develop an enhanced BLDC motor design based on the current brushed DC motor design. The design optimization toolbox is a combination of high fidelity magnetic equivalent circuit (MEC) -based machine models and genetic algorithm (GA) optimization, which allows rapid population-based optimization for complex design problems. This included rigorous system cost and savings analysis.