Electric powertrain manufacturers increasingly build the motor and inverter as one unit to save weight and space, which adds engineering complexity. EMPEL Systems, UK-based developer of electric propulsion technologies, builds these integrated systems for automotive, aerospace, and industrial use. Without a large R&D budget to support multiple rounds of physical prototyping, EMPEL turned to PDSVISION to bring in Ansys simulation tools:
- Ansys Motor-CAD is used test early design variants, comparing efficiency, power density, and thermal performance
- Maxwell modeled electromagnetic fields in the stator and rotor to reduce energy losses
- Fluent traced airflow and heat through the unit, revealing hotspots that needed better cooling
- Mechanical aims to check components under vibration and load, flagging weak points before prototyping
The simulation-led approach enabled virtual validation of multiple design iterations before manufacturing and supported the development of EMPEL’s integrated electric powertrain systems.
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