A new class of brushless electric machines with axial magnetic flux (BMAF) is actively developing for small and medium-power drives. Firstly, they had special and military applications, but now they are widely used in industry. This type of electrical machines becomes competitive with traditional electric machines. Practice makes us develop systems for the optimal design of this class of electrical machines. The Department of Theoretical Fundamentals of Electrotechnology, SUSU, developed a software package for the design of various types of the BMAF, which implements multi-level optimization, analysis of magnetic and thermal fields, solid 3D models, analysis of circuit solutions. The developed complex is a professional design tool, which have to be included in a larger system of end-to-end design system for machines of this class. It allows solving complex tasks for different project situations. Structurally, it consists of two parts. It is a synthesis system and an analysis system. The synthesis system implements the creation of optimal geometry. The analysis system is based on the technology of digital twins. The digital copy of the electric machine is created using the finite element method. This model is used to assess the magnetic and thermal state and correctness of circuit solutions. This article presents the analysis system.

A new class of brushless electric machines with axial magnetic flux (BMAF) is being actively developed for small and medium-power drives. Firstly, they had special and military applications, but now they are widely used in industry. This type of electrical machines is competing with traditional electric machines. Practice makes us develop systems for the optimal design of this class of electrical machines. The article describes a method for the estimation of axial flux permanent magnet synchronous generators with segment magnets and trapezoid coils, based on the charts, calculated with a special program, developed by the Department of Theoretical Fundamentals of Electrotechnology, SUSU. The variables, describing the motor dimensions, are the outer and inner diameters, height of coils and magnets, number of pole pairs. Other parameters depend on these ones or supplied by technology. The developed method of estimation provides a quick-time calculation of the axial motor design in engineering practice. This article presents the main results of this work.

The article presents the method of synthesis and analysis of the brushless motor with claw-poles. The motor is designed for the pilger mill drive for manufacturing seamless tubes. The peculiarity of the drive is that electric machines of this class for high power have not yet been used in world practice. In this regard, a very thorough analysis of the designed motor is required to remove technical risks in the manufacture of prototypes. For design of this motor the synthesis system and the analysis system were developed. The synthesis system is developed on the basis of nonlinear programming methods. For the analysis, it is proposed to use the program Ansys Electronics Desktop, which implements the finite element method. The peculiarity of using this program is the need to use large computer resources. Herewith, the calculation time of the main characteristics is often not acceptable for practical calculations and takes several hours. The authors propose a simplification of the computational model without significantly reducing the accuracy of the calculation. The brushless motor with claw-poles is replaced by a brushless motor with tangential magnets. The stator designs and the magnetic fluxes of the motors are the same. The effectiveness of such a replacement is shown in the real project. Calculation time with acceptable quality is reduced to a few minutes. This approach is recommended for the creation of design systems of other types of brushless machines. This scientific research was carried out for a real customer.

The development of systems with permanent magnets requires improving their calculation methods. At present, it is impossible to create complex devices with high energy parameters without accurate methods of calculation of the magnetic field and optimization calculations. The calculation of the magnetic field demands the complex digital model with using the finite element method. The optimization methods demand a lot of calculation cycles when optimal parameters are selected. So, on the one hand, the mathematical model has to have a very simple method of calculating the magnet field parameters, but on the other hand, this model must be very accurate. We have a conflict in this case. Simple models have a bad precision but they calculate the magnet parameters very quickly and it is possible to use these methods for optimization circles. Complex methods using the Ansys, Cosmos etc. software have an excellent accuracy, but they demand great computer resources and a lot of time for their operation. It is impossible to use them for optimization circles. In this article, the method, which can solve this problem, is suggested. The method is based on the finite element method to create the digital model of magnet system, but for the realization of this method not a large number of elements is used. So, this method is simple and has a good accuracy. It is possible to use this method for optimization models to design systems with permanent magnets.

The article shows an attempt to create a computer-aided design of brushless direct current machines. The system is built from two stages of design. The synthesis of the geometry of an electric machine is the first stage. The analysis of the obtained characteristics is the second stage of the automated system. The article presents the synthesis stage. The single-criterion optimization method is taken as a basis. The concept of optimization level is introduced. Optimization of different levels involves fixing independent variables for different project situations. The introduction of levels makes the design system flexible. The developer has the ability to calculate a large number of optimal options. The method of sorting variables includes the Fibonacci Method and the coordinate descent method. The system was used in the design of brushless direct current machines of low and medium power and showed good results.

The article is devoted to the selection of the optimal variant of the pilgrim mill drive motor for producing seamless tubes of large diameter. Four groups of variants are presented: using a high-speed electric motor with a reducer, using a low-speed electric motor without a reducer replacing the existing electric motor, using a flywheel as the rotor of a new electric motor, with the exception of a flywheel and replacing it with an electric motor with an equivalent inertial mass. For all variants, the program of accurate calculation of electric machines based on the finite element method ANSYS Electronics Desktop was used. The comparative analysis of the chosen variants is carried out. The minimum consumption of active materials and energy indicators were chosen as indicators of the best option. To replace the existing morally and physically obsolete collector DC electric motor, a drive on the basis of a valve electric motor with claw-shaped poles with permanent magnets is proposed, which has a higher reliability due to contactless current supply, minimum copper consumption, better energy performance, by eliminating excitation losses.