Magnetic refrigerators require superconducting magnets to generate high magnetic fields, but measures to tackle the AC losses present a major challenge.
Analyses must model the superconducting coils to obtain the AC losses of magnetic refrigerators because the currents and magnetic fields of the superconducting coils vary due to the relative positions of the magnetic materials. This case study provides an overview and presents the results for the AC losses of superconducting magnets obtained using JMAG.

Kawasaki Heavy Industries, Ltd.

Senior Researcher, Mechanical System Research Department, Technical Institute, Corporate Technology Division

Mr. Yuki Kihira

More widespread use of AI and smartphones are quickly increasing the amount of power used by data centers. Higher power consumption is driving the need for power sources that can provide better power conversion efficiency. A higher coupling coefficient in power transformers is one challenge that stands in the way of increasing this power conversion efficiency. A low coupling coefficient causes a wide range of problems from inefficiency due to leakage flux to more power surges and noise. This case study ran shape optimizations of core geometry to take full advantage of the greater malleability of powdered metallurgy in order to improve the coupling coefficient.

DIAMET CORPORATION

Advanced Development Sect., Research & Development Dept.

Mr. Ryosuke Takayama

This presentation introduces a method to achieve Model Based Development in the design of Magnetorheological Rotary Dampers (MRDT) using JMAG simulations. By identifying magnetic flux bottlenecks in the traditional design process and conducting parametric studies on geometry and coil turns, optimal design proposals were investigated. As a result, mass reduction and improved response time were achieved.
This approach demonstrates the first step toward improving design efficiency without relying on physical prototypes.

THK CO., LTD.

Automotive Product Development Engineer, Mobility Development Department Research Center

Mr. Priyo Bayu Ramadhan

With the aim of achieving carbon neutrality by 2050, the railway sector—already an energy-efficient mode of transportation—is advancing technological development for further energy savings. Squirrel-cage induction motors are the most widely used drive motors in modern rolling stocks, so improving their energy efficiency has a significant impact. We will present the results of studies on the reduction of losses and torque pulsation by inserting magnetic wedges into the stator slots of the multi-slot high-efficiency induction motor we have been developing. These results were obtained through the JMAG analysis using a large-scale FEA model.

Railway Technical Research Institute

Senior Researcher, Magnetic Levitation Lab., Maglev Systems Technology Div.

Mr. Hiroshi Yoda

Induction heaters using superconducting magnets rotate workpieces in a strong magnetic field to induce current and heat workpieces through Joule heating. Engineers must devise complex designs while developing induction heater. Some considerations include how to achieve magnetic field distributions that can realize the necessary heating performance, identifying and adjusting the electromagnetic force acting on each part, examining the torque characteristics necessary to rotate the workpiece, and the influence the magnetic field produced by the current induced in the workpiece affects the coil. Our case study takes advantage of various JMAG analyses as a means to advance induction heater development. This presentation provides on overview of that work.

TERAL Inc.

Deputy General Manager, Technical Headquarters

Dr. Tetsuya Ito

Optimization is adopted as a means of improving product‐design efficiency. It requires numerous evaluations, so that a making computational‐cost reduction is critical challenge for practical applications. JMAG provides both functionality and license called PSL that enable distributed processing of multiple designs on an HPC system from geometry modification through solver execution. In this presentation, we outline the high‐speed optimization workflow utilizing HPC‐based distributed processing and report results of a significant reduction in computation time compared with traditional sequential methods.

DENSO CORPORATION

Project Assistant Manager, CAE Eng. Dept. / Product Design Key Technology R&D Div.

Dr. Takuya Yoshioka

With the advancement of electrification and the use of wide bandgap power devices, which is one of the keys, it is necessary to analyze and evaluate the frequency range from DC to over 100 kHz electrically and magnetically. On the other hand, except for a part of problems in the high-frequency range such as axial voltage and surge voltage, analyses and designs of the motors have been promoted by nonlinear eddy current fields simulations in the low-frequency range in the past. In the frequency band above 100 kHz, the capacitive behavior caused by the motor structure and the low-frequency range behavior cannot be separated, and the possibility of system design with the inverter increases.
Based on the background, the presenter will describe the issues regarding the analysis and the design of the motors and their systems. In the presentation, examples of both the wide frequency band motor models and related noise analysis for the motor system operations will be shown.

Nagoya University

Designeted Professor, Institute of Material and Systems for Sustainability

Dr. Kazumasa Ide, P.E.Jp (Electrical & Electronics Engineering)

Plastic-bonded magnets offer greater design flexibility and orientation freedom, although their magnetic characteristics are lower than those of sintered magnets. When an external magnetic field is applied during the molding process, bonded magnets can be oriented in a specific direction (anisotropic orientation), achieving motor performance comparable to that of sintered magnets.
However, outline designs using the JMAG material database present challenges because the simulation results often diverge from actual measurements due to incomplete magnetization, which is commonly observed in anisotropic designs. Therefore, we have developed a magnetization analysis method that accounts for orientation direction — the primary factor contributing to the divergence between simulated and measured results. This case study introduces an example of an IPM motor design intended for an automotive auxiliary motor application.

NICHIA CORPORATION

Assistant Research Scientist, Engineering Group, Magnet Manufacturing Dept., Functional Materials Production Division

Ms. Rie Yoshida

Motors consume a majority of the world’s electric power, heightening demand for better motor performance. Engineers commonly use geometry optimizations to optimize the stator and rotor geometries in order to increase motor performance. However, the need to acquire data for the torque, torque ripple, linkage flux, inductance and various other motor characteristics for a variety for geometry patterns requires significant time.
This case study successfully runs a geometry optimization more quickly using dimensional parameters by replacing the FEM analysis with a surrogate model created in advance that predicts the motor characteristics. We also drastically reduced the workload necessary to acquire the data to configure surrogate models through parallel processing done using the JMAG Power Simulation License. Our presentation provides specific examples on both these efforts.

Nidec Corporation

Research 1, Nidec Product Technology R&D Center

Mr. Daisuke Nakagawa

The aim to achieve carbon neutrality is driving development to enhance design accuracy that can enable higher efficiency in induction motors. Three-dimensional analyses that can account for the end effects are essential to highly accurate induction motor design.
Two-dimensional analyses that only evaluate cross-sections struggle to precisely reproduce the magnetic flux distribution of actual induction machines, especially those with skew configurations.
This case study examined losses and torque characteristics using three-dimensional magnetic field analyses to evaluate analysis accuracy. We placed particular emphasis on comparing the effects that temperature dependence and leakage inductance have on rotor conductors.
Our presentation also examines the time required to run three-dimensional analyses using auto mesh and extruded mesh as well as the ability to accurately reproduce motor characteristics.

Fuji Electric Co., Ltd.

Rotating Machine Development Department, Rotating Machine Development Center, Development Division Industry Business Group

Ms. Aiko Kubota

This case study introduces technologies to explore electronic power train designs during the product planning stage to realize the all-in-one process advocated by the Mazda Motor Corporation. The workflow combines methods to configure new motor models derived using the cross-section from motor specifications together with JMAG optimizations. We also examine the potential this workflow has in supporting decisions on designs during the initial development stage through examples visualizing the relationship between BEV performance, costs, and all-electric range.

Mazda Motor Corporation

Staff Manager, Integrated Control System Development Div.

Mr. Seiji Fukui

In this presentation, we will introduce a method for exploring specifications that efficiently satisfy multiple performance requirements through parametric optimization.
In the development of electric vehicle motors, manual adjustments take time to derive specifications that resolve conflicting multi-performance issues
In order to reduce the calculation time for multi-performance optimization, we created a machine learning model based on JMAG calculation results, incorporated it into the optimization tool, and performed optimization.

Mazda Motor Corporation

MBD Innovation Dept.

Mr. Koichi Yakawa

This presentation introduces a case study that runs a comprehensive analysis to visualize the vibration response using color maps by combining the electromagnetic excitation force with transfer functions in JMAG. Conventional development processes generally run structural analyses after completing the magnetic circuit design. However, our approach demonstrates the possibilities of conducting comprehensive vibration evaluations with only JMAG.
This method helps understand the vibration characteristics at the initial design stage, which should help reduce the development lead time. As a first step, this case study uses color maps to visualize the vibration response analysis results to examine potential feedback to designs.

MITSUBA Corporation

Team Leader, Technical Development Section1, Research & Technical Development Department

Mr. Takahiro Uchidate

This case study proposes a method to reduce eddy current loss in the stamped sheet coils of coreless axial gap motors to realize a high coil fill rate and high productivity. The design adds slits that alternate perpendicularly to the flow of current to successfully reduce eddy current losses by 36%. However, these machines require three-dimensional analyses that obtain the eddy current losses, which is difficult considering the available lead time. That is why this presentation also examines the effectiveness of the various JMAG parallel processing options to reduce the time required for these analyses.

Mitsubishi electric corporation

Supervisor, Component production engineering center

Mr. Tatsuro Hino

In commercially available electric motorcycles, there is a notable shift in the cooling method, moving from air cooling to water cooling, and in the winding method, moving from concentrated winding to distributed winding, as the output increases. This shift occurs around 8 to 10 kW. However, there is a paucity of empirical investigations examining these combinations to ascertain their optimality.
In order to verify this trend, a verification model utilizing 1D thermal analysis has been constructed which allows for the comparison of the capacity and weight of the motor and cooling system according to the vehicle’s required output and thermal performance. This model reproduces the thermal resistance of each part of the motor, as well as cooling by the radiator and traveling wind, using JMAG’s thermal network, allowing comparison of differences in transient temperature rise according to the motor’s size, weight, and generated losses. A comparison and verification of the combinations of winding methods (concentrated winding or segment conductor distribution winding) and cooling systems (water-cooled or air-cooled) was conducted using the model that had been constructed.
In the motor designed for this study, when the maximum output of the vehicle was 35 kW or less (European A2 license), the total volume of the motor and cooling system was found to be the smallest for the air-cooled concentrated winding motor. However, in the 15 kW and above range, it was found that the volume of the water-cooled Segment conductor (SC) winding motor, including the cooling system (radiator, hoses, pump, reservoir tank, cooling water), was approximately 110％ of the air-cooled concentrated winding motor, and the weight was approximately 65％ or less. In this study, we used a SC winding motor as a type of distributed winding motor for verification. The characteristics of distributed winding motors include a large number of slots that provide a large contact area with the winding and high heat dissipation. These characteristics are the same regardless of the type of winding. Therefore, these findings are generally consistent with the observed trend of an increasing adoption of water-cooled distributed-winding motors in commercially available electric vehicles (EVs) with a power rating of approximately 10 kW.

YAMAHA MOTOR CO., LTD.

Senior Chief, Electric PT Development Division, Electric Development Section, Powertrain Development Center

Mr. Ryota Otaki

Flux-switching motors have the advantage that the permanent magnets can be placed on the stator, which facilitates cooling of the magnets. However, three-dimensional calculations are required, and computational cost is an issue. In recent years, surrogate models have been used in simulations for magnetic design, and optimization in three-dimensional calculations has become a reality with the aid of these models. In this presentation, the result of a study is reported that focuses on accelerating the shape search of axial flux-switching motors with surrogate models.

YANMAR HOLDINGS CO., LTD.

Electric & Electronics Control System Development Division

Mr. Yuto Kimura

In recent years, many high-field applications using the second-generation high-temperature superconductors (HTS) have been developed around the world. As a fundamental experiment, 45.5 Teslas of world-record DC field was generated. 20 Teslas was achieved with a test coil towards the development of compact fusion reactors. Meanwhile, since REBCO conductors are expensive and helium is shortage, it is hard to develop HTS applications with experiments.
Due to such backgrounds, it is important to simulate the phenomenon of HTS magnets for understanding, design, and stability evaluation. In addition, with the proposal of no-insulation winding technique, the electromagnetic behaviors are complicated. The thermal and stress/deformation concerns are also important. Therefore, a high-accurate multi-physics simulation is required for the development of HTS applications.

Hokkaido University

Professor, Faculty of Information Science and Technology

Dr. So Noguchi

Electric vehicles require highly efficient drive motors to extend driving range.
Higher efficiency requires non-oriented electrical steel sheet for use as iron core materials that offer lower iron losses.
However, iron losses in electrical steel drastically increase due to the stress applied during punching, shrink fitting, and other motor assembly processes.
Fabrication technologies and material development are two potential approaches that seek to mitigate these iron losses.
Practical applications as iron core materials already exist for JNEX™ steel sheet with 6.5% uniform silicon content and JNHF™ steel sheet with 6.5% silicon content on the surface layer, significantly suppressing the increase in iron losses due to stress. We mass produce the electrical steel expected to become commonplace in high-efficiency motor applications through a chemical vapor deposition process.
This case study presents an example that evaluates the impact of the shrink fitting stress on IPM motor efficiency and iron losses.
We verify how effectively JNHF™ steel sheet with 6.5% surface silicon suppresses iron loss increases and efficiency drops caused by shrink fitting.
Additionally, we examine its effectiveness through JMAG numerical simulations.

JFE Steel

Senior Researcher, Electrical Steel Research Dept.

Mr. Soichiro Yoshizaki

Thermal management is a critical enabler for next-generation high-performance motors. This presentation will firstly provide an overview of state-of-the-art cooling technologies for electrical machines, highlighting their respective advantages and limitations. Particular focus will be placed on the challenges of thermal modelling and experimental validation, especially for advanced spray and jet cooling methods. Key aspects such as cooling effectiveness, impact on power density and efficiency, as well as manufacturing complexity, will be discussed. The talk will conclude with perspectives on emerging trends and future developments in cooling strategies for automotive electrical machines.

University of Nottingham

Principal Research Fellow, Power Electronics, Machines and Control Research Institute

Dr. FENGYU ZHANG

This presentation introduces a modular, segmented-core design approach for large wind turbine generators aimed at expanding the supply chain and promoting domestic offshore wind deployment. Modularization enables standardized components and distributed manufacturing, making local production feasible.
A 2MW-class vertical-axis generator model is analyzed using JMAG. The concept is validated through a 2D PM partial model, extended to a 3D deployable structure, and further refined with rotor design strategies targeting rare-earth-free solutions.

Albatross technology inc.

CTO

Mr. Masaya Inoue

Large generators are the core equipment of power systems, and inaccurate calculations at the end of large generators affect the safe and reliable operation of the motor. Currently, electromagnetic calculations for generators involve the linear section of the winding in the slot, which has a simple geometric structure, regular winding arrangement, and strong magnetic field symmetry. However, calculations for the end of large generators are difficult. This study reports on the application of JMAG in large steam turbine generators, taking the calculation of losses in the stator end coils and end structural components of a large capacity air cooled generator as an example. Based on the JMAG simulation software, a three-dimensional finite element simulation model of the generator’s stator and rotor end coils and other structural components was constructed, and finite element calculations were carried out. The experimental results were in good agreement with the calculations.

SHANGHAI ELECTRIC POWER GENERATION EQUIPMENT CO., LTD SHANGHAI GENERATOR PLANT

Electrical Engineer, Technology Development Department

Dr. Baichuan Xu

Currently, there are two trends in machine development for electric vehicles. The first is to target high power densities using axial flux machines (AFM), which have become increasingly popular in traction drive systems, especially in the yokeless permanent magnet version (PM-AFM). The second is the reduction of rare earth materials due to supply chain risks and environmental concerns. With upcoming sustainability requirements, external excitation with a wound rotor (EE-RFM) is increasingly used in drivetrain applications. This offers the advantage of rotor speed independent excitation, making it ideal for variable speed drives, as in electric vehicle drivetrains. As a combination, the externally excited axial flux machine (EE-AFM) is introduced in this study.

However, due to added masses mainly from the rotor windings, the rotor stresses and the displacement are a major issue for EE-RFMs and require special attention while designing the machine. For an EE-AFM, the rotating masses do not interact identically, as the centrifugal forces result in additional bending of the carrier while causing stresses that affect both the electromagnetic performance and the structural integrity of the machine.

From electromagnetic perspective, optimizing an EE-AFM is challenging due to the interdependence of numerous parameters. Performance targets such as torque and efficiency are directly influenced by the design of the magnetic circuit and windings. In an EESM, joule losses in the windings of stator and rotor (including ohmic and frequency-dependent effects) and mechanical behavior have the highest impact on duty cycle losses and ultimately driving range of an electric vehicle.

Connecting these domains and demands is mandatory in the Multiphysics design optimization of EEAFMs. For time-efficient calculations leading to extensive parameter studies, typical 3D simulations of the electromagnetic, mechanical and aerodynamic domains must be avoided as much as possible. In this work, several valid simplifications and model reductions have led to a significant reduction in simulation time while maintaining precise results.

Electromagnetically, the 2D circumferential sliced models are already known and well researched. The advantage of this method is the fast calculation and simultaneous representation of physical results such as nonlinear saturation behavior from the magnetic characteristics of the silicon steel laminations. The simulated torque and losses of the electric machine are assessed and verified for their prediction accuracy. Another 2D simplified model, perpendicular to the electromagnetic one is used to analyze the displacement and stress within the rotating system and is validated with detailed 3D models. Finally, 3D CFD simulations provide insights into airflow patterns and especially drag losses, relevant for the loss calculations.

The proposed holistic design workflow can be used to find the optima for a given requirement on the component level. By extending the degree of freedom with variable gearbox ratios, the most suitable powertrain setup and architecture can be determined. This study highlights the importance of Multiphysics design optimization to maximize the performance and reliability (-60% of displacement possible) of EE-AFMs as demonstrated in the graphs below. Incorporating aerodynamic drag analysis alongside electromagnetic and mechanical considerations offers improved efficiency and extended lifetime for electric mobility applications.

Schaeffler AG

Head CoC Electric Machines, Technology & Innovation

Dr. Martin Bruell

Our company is developing high-speed motors that enable gearless direct-drive systems, contributing to the realization of a carbon-neutral society. As part of this effort, we are pursuing the development of even higher-speed and larger-capacity motors, and are examining the applicability of induction motors. To accommodate increased rotor speed, the adoption of a solid rotor—where the rotor core and secondary conductor are formed as a single block—is being considered. However, solid rotors raise concerns about increased eddy current losses, and detailed evaluation and countermeasure studies require three-dimensional electromagnetic analysis.
In this presentation, we will introduce the results of analyzing eddy current losses in squirrel-cage induction motors with solid rotors using both two-dimensional and three-dimensional electromagnetic field simulations.

MEIDENSHA CORPORATION

Senior Engineer, Power Electronics & Drive Systems Research Dept., Advanced Technology Research Laboratories, Research & Development Group

Mr. Sho Uchiyama

As the demand for motor design rapidly increases with the acceleration of electrification, the shortage of design engineers and the need for shortened development cycles are becoming more pressing. To address these challenges, we have been developing a “Motor Design Agent” that leverages our proprietary generative AI technology.
In this presentation, we will introduce an autonomous motor design and development process integrated with JMAG-Designer. In this system, AI agents work in conjunction with JMAG-Designer to automatically execute the entire design workflow, from initial concept ideation, CAD model creation, and analysis condition setup, to design optimization and result evaluation. Furthermore, we will present case studies of motor design projects conducted in collaboration with Toyota Motor Corporation, Daikin Industries, and Mitsubishi Heavy Industries.

MotorAI Inc.

CEO

Dr. Yuki Shimizu

Modern electric motor design demands a shift from single-point analysis to comprehensive design space exploration. However, executing the hundreds or thousands of simulations required for multi-objective optimization, efficiency mapping, and data-driven design is often unrealistic due to computational resource constraints. This presentation introduces a turnkey cloud HPC platform enabling JMAG users to overcome these bottlenecks. Through a case study of an EV drive motor, we will concretely demonstrate methods for automating and parallelizing a Design of Experiments (DOE) involving 1,000 points. We will also explain how to seamlessly access diverse hardware architectures—from multi-core CPUs suitable for FEA to the latest GPUs—and find the optimal cost-performance ratio for each job. This session provides practical strategies for JMAG engineers to dramatically reduce design cycle times, increase simulation throughput by over tenfold, and accelerate the path to true simulation-driven virtual prototyping.

Rescale Japan Co., Ltd.

Director, Technical

Mr. Hitoshi Sato

The flux modulation magnetic gear was proposed in 2001, and it has been reported to achieve a significantly higher torque transmission density compared to conventional magnetic gears. In addition to its characteristics such as high efficiency, quiet drive, and low hysteresis loss, it possesses unique features not found in mechanical gears, including a greaseless drive, step-out torque, and compliance.
However, unexpected cogging torque components were observed in prototype testing, potentially degrading these benefits.
This study aims to reduce cogging torque through a comprehensive evaluation based on theoretical investigation, magnetic field analysis, and experimental testing.
The results identified assembly errors as a primary cause and confirmed that harmonic suppression via magnet skewing is an effective countermeasure.

Sumitomo Heavy Industries, Ltd.

Electromagnetic Actuator Sec. Electromechanical Control Technology Dept., Technology Research Center

Mr. Hiroki Nakagawa

In this presentation, we will discuss vibration simulation of rotational machinery systems, including motors. To more accurately predict the vibrational behavior of a system, we propose a method for modeling the entire system using 1D CAE.
Specifically, we will focus on rolling bearings, and present analysis results from a model that incorporates their stiffness, as well as case studies on suppressing bearing-induced vibrations.
Additionally, we will explain the relationship between bearing stiffness, which changes with torque conditions, and the resulting natural frequency of the entire system.

NewtonWorks Corporation

Chief, CAE Research & Development Center

Mr. Hiroki Sasaki

We will introduce the basic features of Acoustic Simulation Software≪Actran≫.
In addition, we will present the noise analysis functionality for electric motors (Workflow Manager), which can be integrated with JMAG, along with examples of its application.

Hexagon

Principal Engineer, D&E Systems Technical Solutions

Mr. Koichiro Yamamura

Torque ripple remains a critical challenge for precision control and NVH optimization in electric drive systems. While finite element (FEM) analysis using JMAG Designer accurately captures spatial harmonics and magnetic saturation effects, incorporating inverter switching dynamics often results in impractically long simulation times.
We present a real-time Hardware-in-the-Loop (HIL) methodology that combines JMAG-RT FEM motor data with a high-fidelity switching inverter model implemented in Simulink® and Simscape™ Electrical™. The resulting model runs on a Speedgoat HIL test system featuring a programmable FPGA I/O module, enabling sub-microsecond time steps while preserving all torque ripple contributions.
The complete workflow is addressed, supporting both Controller-HIL and Power-HIL configurations, to verify that production-ready control software and hardware achieve minimal torque ripple levels. The proposed methodology enables faster and more repeatable validation under realistic conditions, significantly reducing development cycle time and improving quality assurance.

Speedgoat GmbH

Senior Application Engineer, Application Engineering

Dr. Lu-Dac