E-Motor Design
Design, calculation and optimization of electric motors – from concept to series-ready solution.
CME selects the right electric motor for your application and optimizes the design according to your specifications. Our experts calculate and simulate magnetic circuits, lamination cuts and thermal loads – for motors with particularly high efficiency, even under harsh environmental conditions and at high temperatures. Through the close integration of e-motor design, power electronics and control engineering, optimally coordinated drive systems are created.
Design of EC, DC and synchronous machines
- Conceptualization and design of brushless EC motors, DC motors and PMSM
- Dimensioning of torque, speed, efficiency and frame size per load profile
- Adaptation to operating conditions: continuous, peak load, intermittent duty
- Development of custom motor geometries for OEM applications
Magnetic circuit geometry design (rotor & stator)
- Design of rotor and stator geometry for optimal magnetic flux
- Slot geometry, winding scheme and pole count optimization
- Minimization of cogging torque and torque ripple
- Use of permanent magnets (ferrite, NdFeB) per thermal and cost requirements
Lamination construction
- Design of stamping geometries for rotor and stator laminations
- Material selection (e.g. NO20, M270-35A) per loss specifications
- Optimization of lamination stacking for manufacturing efficiency and tolerance robustness
- Consideration of stamping process and tooling design in the construction phase
Design for high-temperature applications
- Motor dimensioning for continuous operation at elevated ambient temperatures (up to 180 °C+)
- Selection of temperature-stable materials: insulation class H/C, high-temperature magnets
- Thermal simulation and validation in operating profile
- Qualification for automotive and industrial high-load applications
Electromagnetic FEM simulation (Motor-CAD / ANSYS)
- Numerical field calculation with Motor-CAD and ANSYS Maxwell
- Analysis of flux density, eddy current losses and saturation behavior
- Thermal-electromagnetic co-simulation for realistic operating points
- Iterative optimization of geometry and winding based on simulation results
Analytical calculation & optimization
- Analytical design per common machine equations (Kp, Ke, L, R)
- Efficiency optimization across entire speed/torque characteristic
- Loss breakdown: copper losses, iron losses, mechanical losses
- Comparison of analytical results with simulation data and measurements
Application-specific motor selection
- Requirements analysis and load profile evaluation for optimal motor topology
- Comparison and assessment of standard motors vs. custom development
- Total cost of ownership analysis incl. energy costs and lifetime
- Manufacturer-independent consulting and qualification of suitable drive solutions
Integration with power electronics & control
- System coordination between motor, inverter and control algorithm
- Design of DC link, shunt measurement and gate driver topology
- Tuning of PWM frequency, dead time and EMC behavior to the motor
- Validation of the overall system in hardware-in-the-loop operation
Drive strategies for EC motors (efficiency, noise, robustness)
- Implementation of FOC, MTPA and field weakening for extended speed range
- Noise-optimized control through harmonic minimization and random PWM
- Sensorless speed/position detection (BEMF, HF injection)
- Robustness strategies: short-circuit protection, temperature limiting, fault tolerance
Clarify feasibility – before costs arise.
Send us your requirements. We evaluate feasibility, risks and timeline – and tell you honestly what works.
Send requirements