Abstract: In order to analyze the thermal behavior and temperature distribution of the flat PM linear motor, and design the cooling system, a 3-D geometric model of the motor is built up using the FEA software ANSYS, and a method of experimental measurement is used. A novel powerful plate-type cooler is designed to integrate into the top of the laminated core and winding ends, while the dimension of motor remains unchanged. Validity of analysis and design methods is verified via the temperature test of the prototype. As a result the temperature of winding is reduced by 50 percent, the life of the linear motor prolonged, and the rated thrust is increased by 18 percent.