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Currently, metallurgical industry contains a large number of morally and physically outdated electrical equipment that requires modernization. It requires a large capital expenditure to replace it. For this reason, it is slow to implement, long-term use for the purpose of payback, and slow to withdraw from manufacturing. In this regard, the new equipment must be innovative and in many respects ahead of the existing level of development of the industry. The article suggests such a solution. To replace the existing collector motor of the pilger mill drive for the manufacturing of seamless pipes, which has been operating since 1928 and is in a critical condition, a large-sized low-speed brushless motor with a large built-in inertial mass is proposed, which has a permanent magnet magnetic system and claw-poles. Such a technical solution for drives of this class has not been used in the world. The motor eliminates the existing 120-ton flywheel, improves reliability due to contactless current supply, and reduces operating costs by eliminating excitation losses. The motor design allows its Assembly without additional tooling, which is very important for large motors with permanent magnets. To develop a unique motor, a design system consisting of a synthesis subsystem and an analysis subsystem was created. The synthesis subsystem implements multi-level single-criteria optimization. As a result of its operation, the optimal geometry is determined based on the selected criterion. The analysis system confirms the calculation reliability using simplified optimization methods and finally removes technical risks before manufacturing an industrial design. It is based on the well-developed Ansys Electronics Desktop and Ansys Icepak systems for CAE electric machines. The analysis has several stages, which includes electromagnetic and thermal analysis. It is based on the well-developed for CAE systems electric machines Ansys Electronics Desktop and Ansys Icepak. The analysis has several stages, which includes electromagnetic and thermal analysis. The effectiveness of the design system was tested on a real project that was performed for the Chelyabinsk rolling mill. This approach is recommended for the design of other similar types of brushless direct current drive.

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