Holistic Optimization: Integrating Mechanical, Electrical, and Ergonomic Design for BLDC Motor-driven Mobility Strategies

Abstract

Long-term adaptability, efficient functioning and performance of BLDC motor-driven mobility systems rely on the mindful combination of their electric subsystem, mechanical architecture, ergonomic interface, and maintenance. The present study is a multi-domain analysis that integrates mechanical, electrical, and human-centered optimization, in order to help in the construction of advanced mobility devices. The proposed work begins with the definition of the system architecture and defining the initial design requirements, such as the specifications of the BLDC motors, gear ratios, structural geometry, and user interfaces. These parameters are discussed with a view to coming up with the best spatial settings as well as functional interdependencies within the system. To help in performance assessment and design optimization, a comprehensive 3D CAD representation was created and connected to multi-physics simulations that included mechanical behavior, electrical performance and the ergonomic interaction. With this type of virtual prototype, it was possible to identify an interference, dimensional-check processes, and accurate investigations of assemblies. It was also used to facilitate iterative enhancement, standardization of parts and initial evaluation of electrical performance and human-machine interface. Simultaneously, an optimization system was introduced to attain high reliability, improved operational efficiency and better user comfort. The design goals were set according to performance goals, efficiency goals and ergonomics, and the optimization strategy took into account mechanical design constraints, electrical power management constraints and interface ergonomics constraints. The combination of CAD modeling with performance simulations and ergonomic analysis allowed obtaining the explicit design requirements and operational recommendations to enhance the usability of the device and minimize the chances of mechanical or user-related errors. Altogether, the suggested holistic solution ensures the reliability of the devices, their better operational performance, cost-effective life cycle management, and user satisfaction. The multi-domain optimization, digital modeling and human-centred design proved to be a systematic and replicable approach that can be used in a broad spectrum of mobility technologies or BLDC motor-driven.