At SOLWIT Engineering and Consultancy, we help our customers validate, ruggedize, and optimize their electromagnetic machinery and power electronics. If your team has already developed a CAD model for a motor, generator, or inverter drive, our advanced multiphysics simulation team serves as your ultimate validation gate. We analyze the complex, coupled physical phenomena acting on your system, identify structural, electromagnetic, or thermal bottlenecks, and deliver tangible engineering solutions.
Our Specialized Simulation Core
1. Electromagnetic (EM) Design & Core Analysis
We use advanced 2D and 3D Finite Element Analysis (FEA) to maximize electromagnetic performance.
- What We Analyze: Flux density distribution, magnetic saturation, cogging torque, torque ripple, core/hysteresis losses, back-EMF waveforms, and demagnetization analysis under peak load and extreme thermal conditions.
- Our Solutions: Optimization of rotor slot geometries, magnet placement (IPMSM vs. SPMSM), skewing strategies to minimize torque ripple, and custom winding topologies to increase the slot fill factor.
2. Thermal & Fluid Dynamics (CFD) Analysis
Electromagnetic losses manifest directly as heat — the leading cause of insulation breakdown and magnet demagnetization. We meticulously map heat generation and dissipation paths.
- What We Analyze: Stator winding hot-spots, rotor eddy current heating, inverter switching losses, and coolant pressure drops.
- Our Solutions: Optimization of cooling jacket geometries (water-jacket or oil-flooded designs), heat sink fin configurations, and material recommendations for enhanced thermal conductivity.
3. Structural & Structural-Inertial Analysis
We ensure your motor housings, shafts, and inverter enclosures can withstand extreme operational and environmental stresses.
- What We Analyze: High-speed rotor centrifugal stresses, torque-induced shear stresses on shafts, bolt pre-loads, and assembly press-fits.
- Our Solutions: Geometric reinforcement of high-stress concentration zones, shaft diameter optimization, and material substitution to reduce weight without compromising strength.
4. Dynamics: Modal, Shock, and Vibration Analysis
Resonance and mechanical shock can destroy bearings, damage permanent magnets, and fatigue electrical interconnects.
- What We Analyze: Natural frequencies (modal analysis) to prevent structural resonance, harmonic response to electromagnetic forces (NVH), and mechanical shock/drop testing simulation.
- Our Solutions: Rotor/stator stiffness modifications to shift critical frequencies outside operational RPM ranges, and design of optimal vibration-damping mounts and structural ribbing.
The SOLWIT Workflow: From CAD to Optimized Reality
Secure CAD Ingestion: You share your 3D CAD models (via secure NDAs) along with operational duty cycles and boundary conditions.
Coupled Multiphysics Solves: We run high-fidelity FEA and CFD, mapping how electromagnetic losses transform into heat, and how that heat affects structural integrity and dynamics.
Design Bottleneck Identification: We isolate regions prone to magnetic saturation, fatigue, thermal runaway, resonance, or structural yielding.
Actionable Engineering Solutions: We deliver a comprehensive engineering report featuring modified CAD geometries, optimized material specs, and specific design recommendations.
Don't leave your product's performance or reliability to guesswork. Partner with our multiphysics simulation team to eliminate magnetic saturation, prevent thermal failures, and guarantee structural integrity.
Submit Your CAD Model for Review