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Engage with...FluxSys

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Engage with...FluxSys

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FluxSys was formed in 2013, from their base in Wellesbourne, Warwickshire they support their UK and international clients with the specification, design and prototyping of a wide range of electric machines and drives.

FluxSys uses its skills, experience and independence within customers’ projects to support their electrification journeys and skills development, utilising knowledge sharing in an open & collaborative manner with like-minded clients and technical experts.

FluxSys was formed in 2013, from their base in Wellesbourne, Warwickshire they support their UK and international clients with the specification, design and prototyping of a wide range of electric machines and drives.

FluxSys uses its skills, experience and independence within customers’ projects to support their electrification journeys and skills development, utilising knowledge sharing in an open & collaborative manner with like-minded clients and technical experts.

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Engage with...FluxSys

  1. 1. Confidential & Copyright FluxSys Ltd 1 11 November 2021 November 2021 Engage with…
  2. 2. Confidential & Copyright FluxSys Ltd 2 Introduction to us: The FluxSys team is led by two experienced practising engineers: Dr. John Reeve (Technical Director) john.reeve@fluxsys.co.uk Dr. Gareth Pugh (Operations Director) gareth.pugh@fluxsys.co.uk Our team of 8 includes electromagnetic and analysis engineers, mechanical and design engineers alongside business support. We have recently recruited again and have several young engineers working remotely from diverse backgrounds
  3. 3. Confidential & Copyright FluxSys Ltd 3 o Design & optimisation of motors and electromagnetic solutions o Turn-key design and review projects o Design consultancy o ConceptEV software for EV system design o Benchmarking of electromagnetic products Electromagnetic Design & Engineering Motor Prototyping & Manufacture Teaching & Training Resources Our Core Activities: o Modular Teaching Motor DriveLAB* featuring interchangeable electromagnetic topologies o Bench-Top Dyno for dynamic motor testing o Technical training for motor designers and practitioners o Promoting pragmatic, hands-on learning o Coaching, mentoring & guidance o 1-off to 1000-off o Build, analyse and test o Machine winding and testing o Custom manufacturing techniques o Design for manufacture
  4. 4. Confidential & Copyright FluxSys Ltd 4 Company Evolution: 2013 FluxSys formed Electromagnetic and mechanical engineering experience joined 20+ yrs powertrain engineering & management experience joined 20+ yrs powertrain business development experience joined Automotive design, prototyping and control of ultra high-dynamic precision actuators Mining – 3.3kV position sensorless inverter control software support Automotive – eMotor design for manufacture Space – eMotor stepper design for satellite Aerospace – eMotor design for high altitude drone propulsion Magnetics – electromagnetic design and optimisation of high torque cycloidal magnetic gearbox Mining – eMotor design for down-shaft application Magnetics – magnetic design for high speed, high temperature automotive hermetic coupling Automotive – eMotor design and prototyping for in-wheel application Control – eMotor design for miniature high performance application Design – eMotor design for new winding technologies Motor Prototyping & Manufacture - for eMotor assembly, test and benchmarking Electromagnetic Design & Engineering – for drive systems and controls Teaching & Training – Courses and DriveLAB* for a broad range of electromagnetic topics & – ConceptEV for eMotor & system design 2021+ Sensing – electromagnetic design for magnetic visual flag level indicator system Training – Visiting lecturing (MSc) and 2- day introductory courses Training– Knowledge transfer and mentoring client teams
  5. 5. Confidential & Copyright FluxSys Ltd 5 Breadth of Experience & Applications: small large low high The FluxSys team has gained a reputation for supporting our clients on a very wide range of electromagnetic designs, analysis and builds. The common link between them all is that they are all ‘special’ and benefit from our open innovation approach o Miniature stepper motor design for satellite application requiring high torque density, design for extreme conditions and reliability o High power generator design for down-hole application with extreme long-thin form factor and design for harsh conditions (e.g. 160oC ‘coolant’) o Automotive traction motor design for manufacture, modifying electromagnetic design to take advantage of next generation winding process technology and many more…. o Clean-sheet electromagnetic design for automotive in-wheel motor, collaborating and developing client’s in-house team o Electromagnetic simulation for client-developed innovative NDT application
  6. 6. Confidential & Copyright FluxSys Ltd 6 Our Teaching & Training Products: Training o 2-day “Advanced Introduction to Electric Machines & Drives” o Open sessions or in-house dedicated events o 40hr MSc module Currently supporting a number of universities and companies to develop their PEMD training o Tailoring and integration of courses o Visiting lecturing & ‘train the trainer’ DriveLAB* Modular benchtop PEMD training system o Designed ground-up to support learning outcomes o Supported by a growing range of demonstration hardware as used in our own courses
  7. 7. Confidential & Copyright FluxSys Ltd 7 Our Solution to Powertrain Systems Engineering: o Software dedicated to supporting true systems engineering for all involved in electrified powertrains o Benefited from APC TDAP Wave 3 support to validate and develop the concept to product o Developing in partnership with Motor Design Ltd (developers of Ansys MotorCAD) o Currently in internal ‘alpha’ release o External beta release Feb 2022
  8. 8. Confidential & Copyright FluxSys Ltd 8 Recent PEMD activities (last 2 years) o Completed a design for manufacture study between two very large companies (OEM and Tier1) o Acted as a system integration advisor to 3 large companies o Designed several unique motors from scratch – including prototyping o Investigated electromagnetic and electrostatic problems – not all motors! o Investigated options for modifying existing motors for custom applications o Delivered multi-day training courses o Developed training courses & events o Continued development of DriveLAB* modular teaching motor and ConceptEV software products o Supported companies to build up their own PEMD teams o Signposted PEMD teams to recommended suppliers and collaborators
  9. 9. Confidential & Copyright FluxSys Ltd 9 Challenges o As a microSME, customer demand can be difficult to predict or manage even in a periods of increased electrification interest. Our ideal relationships are those that include repeat business or ongoing technical service agreements where we can best support the customers with improved staff availability, responsiveness and technical capability. o As a small company we risk being overwhelmed by large OEM companies (documentation, process, gateways etc.) even though we may hold the specialist knowledge and flexibility they require. o At times, our customers require us to have very specific software or versions of license to match to theirs which can be challenging for a single project. o There are occasions when we need to call upon fellow microSME and SME companies to support us or to complement our capabilities. This requires good contacts and maintaining relationships over time, and clients to be open to it. o As a small company, requests for multiple quotations or quote modifications can be disproportionate to the project in question. o The recruitment and retention of skilled and flexible staff is particularly important in a small SME where staff are required to undertake many roles.
  10. 10. Confidential & Copyright FluxSys Ltd 10 Opportunities o There is currently a very large, and increasing, draw on the need for training and instruction in electrification topics o There is a large and active group of microSME and SME companies operating in the UK o The industry (customers) are calling for a wide variety of electrified powertrain components, systems, simulations, design, training and consultancy o The current level of experience and level of knowledge in the electrified powertrain topics within industry is typically low due to recent rapid industry changes ( sudden need for reskilling) and disjointed academic subjects (need for upskilling - electrification is not covered by any one academic discipline). It’s a system problem!
  11. 11. Confidential & Copyright FluxSys Ltd 11 How can we support the PEMD industry? o We exist as a UK-based company offering specialist electromagnetic and electric machines design services and capabilities in an independent and pragmatic manner o We specialise in electromagnetic topics, electrified powertrain topics and the training and explanation of them for upskilling and re-skilling activities o Our unique selling point is that we’re very well rounded in our discipline: we’re qualified, experienced, pragmatic and willing & able to share information and knowledge o Are there any other equivalent or complimentary companies (viewing this presentation) who’d like to collaborate on similar subjects or have gaps in their services that we may be able to support each other with? o We expect our products (training courses, DriveLAB* and ConceptEV) to deliver substantial positive impact – “punching above our weight”
  12. 12. Confidential & Copyright FluxSys Ltd 12 How can the PEMD industry support us? o We hope customers will understand that it is in their best interest to engage with engineering and technical teams who are practicing these topics on a daily basis, including small ones like us. By maintaining up to date practices, tools, techniques and experience; customers benefit from quick and pragmatic solutions to their projects. o As a small company we’d love to engage with government funding but it really needs to have appropriate accessibility, appropriate intensity and typically be ‘micro funding’. e.g. DER “Building Talent for the Future” would be a good example o We’d like to remind larger companies that we have the technical capability, the flexibility and the experience to be able to support them but not necessarily the administrative support – hence accessibility and engagement processes need to be appropriate o Regular (informal) connection points such as platforms like this enable companies like us to openly discuss how we can play an active part in the PEMD industry
  13. 13. Confidential & Copyright FluxSys Ltd 13 FluxSys within the PEMD industry FluxSys Electromagnetic Design & Engineering – for drive systems and controls We can offer: Teaching & Training – Courses and DriveLAB* for a broad range of electromagnetic topics & ConceptEV for e-powertrain system design Motor Prototyping & Manufacture - for eMotor assembly, test and benchmarking We need: Appropriate access and intensity to ‘micro funding’ Appropriate accessibility and engagement processes with larger companies ‘Big’ industry to engage with small, pragmatic and experienced specialist companies like us
  14. 14. Confidential & Copyright FluxSys Ltd 14 Technical Strategy & Vision: o As passionate engineers, promote the education and training of others either directly through professional development courses or indirectly through supply of teaching products In the field of Electromagnetic Design, Consultancy and Teaching &Training Products FluxSys will…. 2021+ o Strive, through collaborative relationships, to explore, support and educate its partners; delivering high-value tangible outcomes for real world challenges o Apply knowledge, experience, passion & fresh innovative relevant thinking to increasingly diverse electrification projects and technical challenges We have a wide variety of case studies available and we’d be happy to discuss these with you
  15. 15. Confidential & Copyright FluxSys Ltd 15 The FluxSys team looks forward to hearing from you o FluxSys Limited o +44 (0) 2476 920800 o Warwick Innovation Campus Wellesbourne CV35 9EF United Kingdom o info@fluxsys.co.uk Dr. John Reeve (Technical Director) john.reeve@fluxsys.co.uk Dr. Gareth Pugh (Operations Director) gareth.pugh@fluxsys.co.uk

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