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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11 November 2021
November 2021
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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

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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

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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

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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

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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

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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

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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

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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.

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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!

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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”

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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

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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

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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

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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