Synchronous Wound Field Machine Design Procedure using Ansys Motor-CAD​ Software (Tutorial)

This tutorial presents a step‑by‑step workflow for designing a Synchronous Wound Field Machine (WFSM) using the Ansys Motor-CAD® dedicated electric motor design tool for multiphysics simulation. You are guided through the full design process, from specification and initial sizing to electromagnetic, thermal, mechanical, and NVH analysis. 

The tutorial shows how Ansys Motor‑CAD software E‑Magnetic, Lab, Thermal, and Mechanical modules are used together to evaluate performance, losses, cooling, structural integrity, and noise. Design choices are explained throughout, linking machine theory with practical engineering trade‑offs in a clear and structured way.

Learning Outcomes:

Following completion of this tutorial, you will be able to: 

• Interpret a machine specification and translate performance, thermal, and packaging requirements into initial design targets for a synchronous wound field machine. 
• Apply initial sizing methods to estimate key dimensions, magnetic loading, and electric loading as a starting point for Ansys Motor‑CAD software models. 
• Select and justify machine topology choices, including winding type, rotor type, number of phases, and slot/pole combinations, based on performance and manufacturability trade‑offs. 
• Build and evaluate electromagnetic models in Ansys Motor‑CAD software to assess torque production, back‑EMF, saturation, losses, and Maximum Torque Per Ampere (MTPA) operation. 
• Analyze peak and continuous performance using the Lab module, including torque‑speed envelopes, efficiency maps, and control strategy effects.
• Set up and interpret thermal models to assess cooling strategies, winding temperatures, and continuous operating limits under realistic loss conditions.
• Assess mechanical integrity and NVH performance, including rotor stress, safety factors, electromagnetic forces, vibration response, and acoustic behaviour. 

Please note: These training materials were developed and tested in the 2025R1 release.