Saadat H.
Motor Development Intern
Experience
Oct 2024 - Feb 2025
5 monthsWegberg, Germany
Motor Development Intern
Denso Europe
- Carried out FEM simulations of a novel brushless externally excited synchronous motor with JMAG to reduce iron losses by 8%
- Developed MATLAB scripts to optimize the total loss profiles based on machine parameters
- Developed a Python-based GUI tool for calculating optimal motor design parameters
- Created Python scripts in JMAG to automate and improve simulation processes
Aug 2024 - Feb 2025
7 monthsAachen, Germany
Master Thesis, Production Engineering of E-Mobility Components
RWTH Aachen University
- Conducted a benchmarking study on 30 EV models (2018–2023) to evaluate product and manufacturing technologies of PMSM, IM, and EESM topologies
- Analyzed drive architectures to correlate mechanical integration and component interfaces with overall power density and efficiency
- Analyzed stator and rotor design methods, compared joining and lamination technologies to evaluate the impact on magnetic losses and mechanical integrity
- Investigated modern winding technologies (U-hairpin, I-pin, X-pin) to identify improvements in copper utilization, insulation design, and electromagnetic performance
- Quantified technological trends in power-to-weight ratio, stator scaling, and conductor segmentation through statistical and comparative data analysis
Jan 2023 - Nov 2023
11 monthsAachen, Germany
Student Assistant
Institute for Electrical Machines, RWTH Aachen
- Designed PMSM motors (surface-mounted, IPM) in 2D/3D with Autodesk Inventor
- Conducted finite element simulations using Ansys Workbench to optimize flux density in a PMSM by 12% by varying magnet geometry
- Developed mathematical models for hysteresis and coercive field strength based on simulation and experimental data with MATLAB
- Calculated eddy current losses in different machine variants using MATLAB
- Automated post-processing of simulations using Python code in Visual Studio
Jan 2023 - Jun 2023
6 monthsAachen, Germany
Student Assistant
Teaching and Research Area Mechatronics in Mobile Propulsion, RWTH Aachen University
- Calibrated vehicle exhaust after-treatment system using real-time HiL simulation model and measurement data
- Enhanced performance of an automotive simulation model in Simulink by testing and debugging engine and exhaust systems
- Validated critical exhaust measurements by comparing data with simulated quantities in dSpace Configuration Desk
Longitudinal Dynamics Simulation of a BEV to predict vehicle energy demand
RWTH Aachen University
- Built a Simulink model of a BEV powertrain driven by a WLTC cycle
- Simulated the model to investigate power flow, state of charge, and transmission data
- Added regenerative braking functionality to the model and compared simulation results for vehicle energy demand with and without regenerative braking using data inspector
- Performed battery dimensioning based on the energy demand output
Rapid Electric Motor Design — Evaluation of an Induction Motor
RWTH Aachen University
- Performed multiphysics simulations of an induction motor in ANSYS Motor CAD to evaluate electromagnetic and thermal performance
- Developed rapid design evaluation workflows to compare motor configurations against performance targets
- Analyzed drive cycle efficiency and loss distribution to optimize torque and thermal behavior
- Integrated cross-domain simulation data to accelerate iterations in electric machine design
Mini Thesis: Evaluation of FEM-based software for simulating the NVH of electric machines
RWTH Aachen, Institute for Power Electronics and Electrical Drives
- Designed 2D and 3D models of a PMSM in JMAG Designer and SolidWorks
- Conducted 3D FE acoustic simulations of PMSM using JMAG to assess electromagnetic force impacts in the stator air-gap
- Implemented MTPA control strategy using a MATLAB-based machine analysis tool to maximize torque output
- Analyzed the structural behavior of the machine by identifying eigenmodes and eigenfrequencies of the PMSM
- Validated eigenfrequencies and acoustic emissions of the machine using Motor-CAD
Summary
Versatile mechanical engineer specializing in electric machine development, FEM-based multiphysics simulation, and Python/MATLAB automation. Strong background in electric drives, industrial motors, robotics actuators, and generator technologies, with proven ability to extract design insights from benchmarking and system analysis. Additional experience in automotive system modeling and HiL validation using Simulink and dSpace. Seeking roles in e-motor design, electromagnetic/FEM simulation, digital engineering, or technical consulting.
Languages
Urdu
NativeEnglish
AdvancedGerman
IntermediateEducation
Oct 2019 - Feb 2025
RWTH Aachen University
M.Sc. Computer Aided Mechanical Engineering · Computer Aided Mechanical Engineering · Aachen, Germany
Aug 2013 - Jun 2017
B.V.Bhoomaraddi College of Engineering and Technology, Hubli
Bachelor of Engineering, Industrial and Production Engineering · Industrial and Production Engineering · Hubballi, India
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