Featured Project

Electromagnetic Actuators

Czero optimizes the design of high-performance automotive components

One of our automotive clients needed a quick turnaround on developing a high-performance electromagnetic actuator. Using knowledge and processes refined during 25+ years in the automotive industry, our engineers saved weeks of R&D time using a smart combination of tools that enabled us to run hundreds of simulations overnight.

Our custom-designed process supports fast iteration

We have developed a streamlined process for designing and optimizing electromechanical actuators and valves quickly and cost-effectively. Additionally, having automated elements of this process, we can iterate through hundreds of actuator designs a day to optimize metrics such as power consumption, energy consumption, maximum current, hold current, actuator speed, actuator acceleration, moving mass, and total mass.

Fast iteration saves our customers time and money

In actuator design project, we evaluated how subtle changes in armature shape affected system performance. Based on this simulation analysis, we were able to make changes that improved performance at no cost. A related analysis enabled us to open up the tolerances on the parts, reducing manufacturing costs for our client.

Elements of Czero actuator design

We combine different CAD, modeling, and dynamic simulation tools for different projects. In the case of actuator design, starting with a base design created from first principles, previous designs, or our own process, we move quickly through these steps:

  • Geometry generation. First, we create solid models for all actuator combinations.
  • Finite Element Analysis (FEA). Next, we run magnetic FEA for each actuator design to create a force and inductance map for the actuator at all combinations of gap and current.
  • System simulation. We feed the force maps from FEA, and other parameters such as inductance, into Simulink models to evaluate system performance metrics, such as closing time and power.
  • Advanced analysis. Then we run Simulink to set the current level to achieve the desired performance, allowing power and other metrics to be compared for equal performance.

Contact Us Today

Reach out to us, schedule a meeting, and let's find your custom solution.

We offer concept-to-prototype mechanical engineering R&D for developing systems and subsystems for cleantech innovations. Learn how we can help your team.