Abstract
Isolated use of electromagnetic or thermal calculations in the design of electrical machines and apparatuses is a significant source of engineering errors since operating modes are formed by interrelated field and thermal processes. The purpose of the study was to substantiate and formalise the approach to integrating automated design with multiphysical modelling by matching electromagnetic and thermal models in a single parametric controlled circuit. The methodology was based on normatively consistent modes, cooling conditions, and temperature limits with two-way iterative coupling and spatially consistent transfer of losses to a thermal model with temperature correction of material properties. As a result, a common parametric frame of inputs is formed, which provides a consistent interpretation of load, cooling, temperature acceptability and energy efficiency. A formalised two-way circuit with convergence criteria provided reproducible stabilisation of temperature maxima and total losses. It is shown that spatial mapping of composite losses preserves local overheating zones, while their reduced transfer smooths out the temperature field. Consistent modelling established the heating domain stratification: in the windings about 130-140°C, in the magnetic circuit 105-115°C, in the housing 85-95°C, in the cooling zone 60-70°C. Temperature corrections of electrical and magnetic parameters substantially change the distribution of losses, primarily due to an increase in the resistance of conductors. A comparison of four matching schemes in 40 scenarios showed a convergence of 26 out of 40 for one-way binding to 38 out of 40 for the integrated solution; a two-way iterative scheme provided 36 out of 40 with stabilisation in 4-7 cycles, while step-by-step co-modelling required 6-12 exchanges. Practical importance lies in the possibility of direct use of the approach to improve the accuracy of thermal checks, select load modes, and optimise design solutions for electrical products