The Module Section is where PiCAD-Motor. While the Getting Started and Admin areas give you the framework and controls, the modules are where you actually build, test, and refine your motor designs. Each module is tailored to a specific type of motor application or design consideration, ensuring that users—from beginners to seasoned engineers—get exactly what they need.
The four main modules are:
EV – Electric Vehicle Motor Applications
Non-EV – Modern Motor Applications and Traditional vs. Modern Comparisons
AMD – Advanced Motor Design Techniques
Cost Calculation – Tools for Project Budget Estimation
Let us explore each one in detail.
1. EV Module – Powering the Future of Mobility
1.1 Overview of EV Motor Applications
The EV module is designed specifically for electric vehicle engineers, researchers, and manufacturers. With EV adoption growing globally, efficiency, performance, and cost-effectiveness of motors have become critical. This module helps users simulate, analyze, and optimize every aspect of an EV motor without needing to build physical prototypes upfront.
When you step into this module, you’re essentially entering a digital laboratory for EV motors—equipped with advanced analytical tools, visualization capabilities, and integrated cost analysis.
1.2 Vehicle Log
The Vehicle Log acts as the project history and quick-access journal for all your EV simulations.
New Vehicle Records: Every time you create a new EV design, it automatically generates an entry in the log.
Categorization: Vehicles can be categorized (e.g., 2-wheeler EV, 4-wheeler EV, bus, commercial vehicle).
Editable Details: Update specifications as your design evolves—like battery capacity, motor rating, or cooling methods.
Version Tracking: Each modification creates a new version entry, ensuring you can backtrack or compare iterations.
1.3 Vehicle Dynamics
The Vehicle Dynamics feature is where physics meets design. Here, you input and validate the key parameters that determine how your EV will behave in real-world conditions.
Inputs: Vehicle mass, wheel radius, aerodynamic drag coefficient, rolling resistance, gradient conditions, and drive cycle patterns.
Outputs: Acceleration time, top speed, power demand curves, energy efficiency under different drive cycles.
Validation: Users can cross-check results against real-world vehicle dynamics equations.
1.4 Motor Wiz – The Core of EV Simulation
The Motor Wiz is the beating heart of the EV module. It provides deep motor analysis across all performance parameters.
Performance Analysis: Torque-speed characteristics, efficiency maps, and power output across operating ranges.
Flux & Winding Analysis: Visualize magnetic flux distribution, winding losses, and hotspot predictions.
Loss Calculations: Separate breakdowns of copper losses, iron losses, eddy currents, and stray load losses.
Cost Estimation: Evaluate the cost of each material (magnets, lamination, windings, cooling ducts, etc.).
Cooling Considerations: Axial cooling duct performance is factored in for thermal optimization.
2. Non-EV Module – Motors Beyond Mobility
2.1 Overview of Modern Motor Applications
Not all motors are built for vehicles. The Non-EV module caters to industries such as manufacturing, robotics, household appliances, and aerospace, where motor design requirements differ.
This module provides a sandbox for designing, analyzing, and optimizing non-automotive motors, ensuring they’re efficient, durable, and cost-effective.
2.2 Comparison of Traditional vs. Modern Motor Technologies
One of the highlights of this module is the side-by-side comparison feature.
Traditional Motors: Characterized by basic winding methods, lower efficiency, higher material wastage.
Modern Motors: Incorporate advanced lamination, optimized flux paths, skewed rotor designs, and lightweight materials.
Comparative Charts: Users can generate charts that clearly show efficiency gains, cost savings, and reduced thermal losses in modern designs.
Scenario Testing: Users can replicate older motor designs and then upgrade them with modern materials to see the difference instantly.
2.3 Technical Features (Flux, Winding, Losses, Cost Estimation)
Just like in the EV module, the Non-EV module provides deep motor analysis:
Flux Studies – Map out how magnetic fields behave in traditional vs. modern layouts.
Winding Schemes – Compare distributed vs. concentrated windings.
Loss Analysis – Identify efficiency bottlenecks.
Cost Estimation – Understand where modern designs may cost more but save energy in the long run.
3. AMD Module – Advanced Motor Design
3.1 Overview
The AMD (Advanced Motor Design) module is for power users and researchers who want to explore cutting-edge motor design techniques.
While the EV and Non-EV modules cover foundational performance metrics, AMD introduces complex design phenomena that significantly influence motor behavior.
3.2 Torque-Speed Curve with Skew & Without Skew
With Skew: Skewed rotors reduce cogging torque and smoothen torque delivery, but may slightly reduce efficiency.
Without Skew: Higher torque ripple but lower manufacturing complexity.
Comparison Graphs: Users can generate torque-speed curves for both cases to visualize trade-offs.
3.3 Motor Constraint Curves with Skew & Without Skew
Constraint curves allow engineers to see operating limits under different load and temperature conditions.
With Skew: Enhanced smoothness under dynamic conditions.
Without Skew: Higher peak torque but increased mechanical stress.
Thermal Limits: Users can apply axial cooling ducts and see how much more stress the motor can withstand.
4. Cost Calculation Module – Making Designs Affordable
4.1 Overview
Designing a motor is not just about performance; it is also about financial feasibility. The Cost Calculation module ensures that engineers do not design a material that is too expensive to produce.
4.2 Cost Components
Machining Costs: Based on complexity of rotor/shaft design, required precision, and finishing processes.
Sheet Metal Costs: Lamination and stamping costs for electrical steels, including wastage factors.
Material Procurement: Pricing of copper, permanent magnets, and specialty steels.
Cooling Integration Costs: Estimating expenses for adding axial cooling ducts or advanced cooling systems.
4.3 Budgeting & Estimation Tools
Scenario Analysis: Compare costs for multiple design versions.
Breakdown Reports: Export cost breakdown per component for transparency.