Multiphysics design optimization of an externally excited axial flux machine
Electromagnetics
PRESENTER:
Lukas Kirzinger, SCHAEFFLER
EXPERTISE:
Electromagnetics
Software:
JMAG
Two key trends shape electric vehicle (EV) machine development: increasing power density with axial flux machines (AFM) and reducing rare earth materials for sustainability. Externally excited wound rotor machines (EE-RFM) address supply chain risks by enabling rotor-speed-independent excitation, ideal for variable-speed EV drives.
Combining these concepts, this study introduces the externally excited axial flux machine (EE-AFM). However, rotor windings add mass, creating stresses and displacement that impact electromagnetic performance and structural integrity. Optimizing EE-AFMs is challenging due to the strong interdependence of electromagnetic, mechanical, and thermal parameters.
Losses in stator and rotor windings, along with mechanical behavior, strongly affect duty cycles and driving range. To enable efficient multiphysics optimization, simplified yet accurate models replace time-consuming full 3D simulations. A 2D electromagnetic model captures torque and magnetic saturation, while a perpendicular 2D mechanical model predicts displacement and stress, both validated by detailed 3D analyses. Complementary 3D CFD simulations evaluate airflow and drag losses.
This holistic workflow identifies optimal component designs and powertrain setups, achieving up to ensured mechanical feasibility and improved efficiency for next-generation EV powertrains.
Other Resources
Private content
Please enter your email to receive the content
On-demand webinars
4 (2) Electromagnetics PRESENTER:Dr. Nithara Narayanan EXPERTISE:Electromagnetics Software:JMAG High efficiency and low cost are some of the challenges on the way to fully electrified car drivetrains to reach a high driving range and low battery cost. The biggest influence on a low loss electric machine is a high copper slot filling factor therefore the concept […]
Private content
Please enter your email to receive the content
On-demand webinars
4 (2) Electromagnetics PRESENTER:Stephan Paul & Zoltan Nadudvari EXPERTISE:Electromagnetics Software:JMAG The electrification of the transportation industry demands the development of power-dense electrical machines that combine high efficiency, optimal material usage, and accelerated time-to-market—critical factors in a highly competitive and rapidly evolving landscape. This creates a significant challenge for design engineers, who are under pressure to […]
Private content
Please enter your email to receive the content
3 (1) Electromagnetics PRESENTER:Srihari Gangaraj & Dheeraj Bobba EXPERTISE:Electromagnetics Software:JMAG Thermal limits directly affect the performance, efficiency, and durability of electric machines. In this webinar, we explore how JMAG integrates detailed electromagnetic loss modeling with advanced thermal simulations to predict coil, magnet, and core temperatures under real-world duty cycles. See how JMAG helps engineers evaluate […]
Private content
Please enter your email to receive the content
On-demand webinars
0 (0) Electromagnetics PRESENTER:Srihari Gangaraj EXPERTISE:Electromagnetics Software:JMAG As robotics systems become more agile and compact, the demands on their electromechanical subsystems are increasing rapidly. From the delicate torque control needed in surgical arms and finger joints to the high-load dynamic response of humanoid legs and autonomous platforms, precision simulation is no longer optional. It has […]
Private content
Please enter your email to receive the content
On-demand webinars
3 (1) Electromagnetics & POwer electronics PRESENTER:Srihari Gangaraj, Guillaume Fontes & Ryoko Imamura EXPERTISE:Electromagnetics & Power Electronics Software:JMAG & SIMBA Electric motors and inverters are central to modern electrification, making their optimization crucial for efficiency, sustainability, and performance. Accurately evaluating losses in both components is a key challenge in motor drive design. This webinar will […]
Private content
Please enter your email to receive the content
On-demand webinars
3 (1) Electromagnetics PRESENTER:Srihari Gangaraj EXPERTISE:Electromagnetics Software:JMAG As manufacturing companies face rising costs and global trade pressures, improving key industrial processes has become critical. Induction heating remains one of the most energy-intensive and capital-driven steps in the production of high-performance components. It is widely used across industries, including automotive, aerospace, heavy machinery, and precision equipment […]
Private content
Please enter your email to receive the content
On-demand webinars
3 (1) Electromagnetics PRESENTER:Didier Zefack EXPERTISE:Electromagnetics Software:JMAG Released in January 2025, the new JMAG-Designer version marks a significant step forward in automation of the design and massive-simulation processes, with boosted and innovative functionalities which make it very easier to use and implant across all design phases of any electric machine types. The key points of […]
Private content
Please enter your email to receive the content
On-demand webinars
0 (0) Electromagnetics PRESENTER:Keerthana C. EXPERTISE:Electromagnetics Software:JMAG The future of axial flux motor simulation is promising, thanks to advancements in computational power, AI integration, and user-friendly software that provide deeper insights and streamline the design process. These innovations are driving the adoption and optimization of axial flux motors across various industries. Axial gap-type motors, known […]
Private content
Please enter your email to receive the content
On-demand webinars
0 (0) Electromagnetics PRESENTER:Stephan Paul EXPERTISE:Electromagnetics Software:JMAG In the field of electromagnetic design, accurately simulating and mitigating eddy current losses is crucial for enhancing the efficiency and performance of magnetic systems. Join us for an insightful webinar where our experts will delve into the latest advancements in simulation techniques. This session will cover the comparative […]
Private content
Please enter your email to receive the content
On-demand webinars
0 (0) Electromagnetics PRESENTER:Stephan Paul & Bernd Cebulski EXPERTISE:Electromagnetics Software:JMAG View this exclusive webinar where Powersys senior engineer, Stephan Paul, will delve into the transformative power of 3D end winding simulations using JMAG-Designer. Discover how accurate calculation of end winding structures can significantly enhance motor efficiency, thermal modeling, and high-speed performance. This webinar will cover […]
On-demand webinars
0 (0) Electromagnetics PRESENTER:Emmanuel Rutovic & Guillaume Fontes EXPERTISE:Power Electronics Software:SIMBA Discover the power of integrated loss analysis in our upcoming webinar featuring SIMBA 24.05 and JMAG-RT. Traditionally, engineers have had to rely on separate tools to evaluate inverter and motor losses. SIMBA changes the game by enabling simultaneous analysis, offering a unified view of […]
2.5 (2) Electromagnetics PRESENTER:Ahmed Shoeb EXPERTISE:Electromagnetics Software:JMAG JMAG-Designer Ver. 23.0 was released on December 2023. JMAG has been developed to automate design. To this end, Ver. 23.0 has further improved functionality so that it can be used in all phases of design, from the initial design phase to detailed design. The processing efficiency of large-scale […]
How useful was this post?
Click on a star to rate it!
Average rating 5 / 5. Vote count: 1
No votes so far! Be the first to rate this post.
