Unifying Design and Multiphysics Simulation for Electric Drive Development

Detailed, physically accurate simulations and virtual twins let engineers evaluate more options for sustainable propulsion systems.

September 1, 2025

Young-Chang Cho

A virtual twin of an electric drive, created within a unified platform, enables efficient optimization of performance across multiple physical domains, including electromagnetics, structure, thermal management, and NVH (noise, vibration and harshness). (Dassault Systèmes)

Electric drive systems are central to the efficient and clean use of energy for electric and hybrid vehicles. They need to efficiently convert electrical energy into mechanical motion, but coupling mechanical and electrical components into a highly compact system requires a range of complex design and engineering tradeoffs.

One challenge is that automotive companies typically use a wide range of design and simulation technologies from different suppliers. This has resulted in multiple iterations of model and data transfers between the design and simulation software, which is inefficient, error-prone, and results in a lack of decision traceability.

A more efficient, accurate, and collaborative approach is the use of unified modeling and simulation within a data-managed platform. This enables development teams to create a virtual twin of the system, providing a consistent reference from functional requirements to concept designs to simulation validations throughout the development process. Examples of connected workflows include:

Electric drive design

Electric drive systems typically include one or more electric machines, gear reducers, and a housing, often with integrated power electronics components. To harmonize component and system-level requirements for optimal performance, modular component design with flexible parametrization is essential. These capabilities, within a unified platform, ensure modeling and simulation continuity across all design stages.

Electric machine design optimizationTo achieve the desired power output while minimizing side effects, such as thermal losses, vibration, and the risk of mechanical failure due to motion and thermal stress, electromagnetic and structural analyses are critical during the initial design stage. Optimizing 2D rotor and stator designs is also essential for subsequent thermal and NVH (noise, vibration, and harshness) analyses and further design refinement.

Electric machine thermal management

Cooling efficiency and auxiliary power for coolant circulation are highly sensitive to the type and design of the cooling system. Effective cooling of electric machines under demanding power conditions is needed to maintain overall efficiency and extend life. Simulation during the design stage helps designers identify and correct problematic hot spots around temperature-sensitive components, reducing problems that could arise during the physical testing stage.

Electric drive NVH

Data connectivity on the platform enables the use of a single source of model data to drive simulations at multiple levels of fidelity. Noise sources originating from electric machines, mechanical components and manufacturing processes can be ID'd earlier in the process, allowing targeted mitigation measures to be applied consistently throughout the development cycle.

Achieving a validated virtual twin

Unified modeling and simulation on a data-managed platform is transforming electric drive system development by providing a seamless, collaborative design and engineering approach. The unified technology provides visualization of the relationship between the system aspects, including requirements, the 3D Model, simulations, and corresponding reports. This approach ensures traceability from top-level requirements, such as vehicle speed and charging time, to specific e-drive technical specifications, such as magnet slot height and angle. By creating a virtual twin and simulating physically accurate performance during the design stage, electric drive developers are able to evaluate more design options to deliver more efficient, reliable and sustainable propulsion systems to the market.

Young-Chang Cho is SIMULIA Industry Process Expert at Dassault Systèmes and wrote this article for SAE Media.