Evaluation and analysis of client projects

Clients often seek advice on manufacturing issues or the feasibility of achieving their aims, particularly with unusual designs.

Our experience of motor technology, across a wide range of industrial applications, means we can provide appropriate and impartial guidance.

Sometimes a client may bring us an underperforming prototype for evaluation, leading to further design work. Occasionally, however, our analysis may reveal that spending more time and budget on a project would be unviable.

Project Management

Tools and processes for successful projects

Difficult and complex projects require detailed planning before work commences and tight control during all design, prototyping and testing stages.

EMX has developed its own project management tools to assist both the design team and client, ensuring that specifications are adhered to and deadlines met with fully tested designs or machines.

Good communication is essential thoughout any project, with clients playing an active role in the management process.


Evaluation of electrical machines

EMX offers clients many kinds of analyses for electrical machines, including:

  • Rapid performance analysis for feasibility or initial design.
  • 2D finite element modelling for design validation and calculation of electromagnetic phenomena such as eddy current losses, unbalanced magnetic pull, iron losses, cogging and ripple torques, inductance and back-emf.
  • 3D finite element modelling when end effects are significant, for instance with ‘pancake’ type motors.
  • Thermal analysis using rapid-analysis MotorCAD software and thermal finite element modelling.
  • Mechanical aspects including interference fits and critical speeds.


Performance, manufacturing and assembly — ######## This needs tidying up

Our design work is normally split into four stages:

  • Specification.
  • Packaging
  • Optimisation
  • Detailed drawings

The specification ensures that all aspects of a machine’s performance and installation have been clearly defined before valuable time is spent on the remaining stages. Packaging work is normally undertaken using 3D CAD software.

Clients can provide models for their own components and assemblies so that mating interfaces to the machine can be developed, before optimisation is carried out, and drawings and documentation finalised.

Design for assembly

Design for assembly takes into account production costs. For example, EMX can tailor the detailed design of a machine to minimise the number of machining operations, or the number of fasteners required to attach components to the final assembly.

Attention to detail at this stage can lead to significant cost reductions during the production run.


Design and procurement from proven suppliers

Our ability to produce a complete set of detailed drawings for a machine design ensures continuity with our network of skilled contractors which manufacture the prototype parts.

EMX can manage these contractors, checking each of the components and assemblies as they become available.

Testing and documentation

Industry standard benchmarking of new and existing products

EMX uses dynamometer equipment, power analysers, insulation testers and power electronic drives for the testing of new or existing machines.

The wide range of performance tests includes the measurement of torque-speed-efficiency, cogging torque and thermal behaviour.

All our tests are fully documented, detailing methods as well as results.

Technology development

Continued development of electrical machine technologies

Keeping abreast of current ideas, techniques and technologies, we invest in our own patentable technologies to give our designs a competitive edge.

Unlike many machine manufacturers, EMX is not tied to a particular technology or production method, and can remain impartial and open minded.

EMX can also assist with, and help develop, new patentable ideas for our clients.

Our links with experts in other, related, technical areas help us understand the full multidisciplinary aspects of these technologies.

Software developement

Bespoke solutions for analysis and design tools

For clients wishing to create a bespoke analysis program for an unusual machine, EMX can help with its development, particularly the engineering code. This can range from relatively simple spreadsheet calculations to standalone design programs.

For larger projects we can hire the services of specialist software houses to assist with interface and database requirements.