Motor Design
Barber-Nichols, Inc. (BNI) designs permanent magnet and switched reluctance motors and alternators for demanding applications. BNI often works on projects where a motor's form factor, efficiency requirement, or speed capability must exceed what is commonly available from standard manufacturers. In these cases, BNI uses Motorsoft SPEED® to design custom motors and alternators which can range in power from fractional Watts to 250 kW and in speed from 1,000 rpm to 200,000 rpm.
Case Study 1:
Barber-Nichols designed and built a Brayton Cycle Powered 3 kW High-Speed Turboalternator. Automotive turbocharger components were modified to provide the gas turbine and compressor. A small, two-pole permanent magnet alternator was then custom designed and manufactured. The alternator used a samarium cobalt ring magnet with a carbon fiber over wrap for magnet retention. The alternator was placed between the turbine and compressor wheel and was cooled with compressed air. The alternator was successfully tested at full power and speed (200,000 rpm).
Case Study 2:
BNI successfully designed and manufactured the transonic fans and associated permanent magnet motors for an unmanned, lighter-than-air vehicle known as a High Altitude Airship (HAA). The HAA will maintain a geostationary position at an altitude of 65,000 feet and the transonic fans control the vehicles internal pressure and cause it to descend when necessary. 
The motor is more than 95% efficient across a 2:1 speed range. The motor design challenge was further magnified by the allowable form factor dictated by the fan hub diameter and by heat transfer issues.
Case Study 3:
Barber-Nichols designed and built a cooling pump and associated sensorless permanent magnet motor for an extended space flight application. The pump is designed to operate in the vacuum of space for 15 years without maintenance. Additionally, restrictive weight and power consumption specifications made the design of this motor extremely challenging.