3D FEM analysis and experimental validation of the transient Magneto-Thermal response of a Permanent-Magnet brake

Purpose This paper aims to develop and experimentally validate a three-dimensional (3D) multiphysics model for predicting the transient magneto-thermal behavior of an axial-flux permanent-magnet (PM) braking system. Design/methodology/approach A coupled 3D finite element model is proposed, combining electromagnetic and transient thermal analyses to account for eddy-current losses, temperature rise and torque reduction. The model includes full geometry and armature reaction effects. A prototype is designed and experimentally tested to validate the approach. Findings The proposed coupled 3D magneto-thermal FEM model shows very good agreement with experimental results, accurately predicting both the transient magnetic field distribution and the temperature-dependent reduction in braking torque. The results confirm the capability of the model to reliably reproduce the real operating behavior of axial-flux PM braking systems. Practical implications The proposed approach provides an efficient tool for the design and optimization of PM braking systems, reducing development time while improving performance prediction. Originality/value The contribution lies in a coupled 3D magneto-thermal framework experimentally validated on a dedicated prototype and integrating full 3D geometry, armature reaction and temperature-dependent effects within a unified multiphysics model.