design, optimization & validation of electric motors …
TRANSCRIPT
Sébastien DESHARNAIS, PhD
Lead Application Engineer
ANSYS Inc.
DESIGN, OPTIMIZATION & VALIDATION OF ELECTRIC MOTORS WITH
ANSYS MOTORCAD & ANSYS MAXWELL
June 1st, 2021
MDL to ANSYS for Complete Design Workflow
Maxwell 2D & 3DAdvanced Magnetics Modeling
Motor-CADEfficient Motor Design
Design Tool
for Electrical
Machines
Mechanical & CFDNVH, Cooling
3D Physical Validation
Concept Design SystemValidation
Design Analysis Operation
System ValidationControl logic, software
MOTOR-CAD
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Motor-CAD
• Combination of analytical andnumerical modelling techniques.
• Covers all typical types of radial fluxrotating electric machines
• Motor Types:
– Brushless permanent magnet
– Induction– Synchronous reluctance– Switched reluctance– Synchronous wound field– Permanent magnet DC– Single phase induction
Motor Design Software
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Motor-CAD EMag
• Combined 2D finite element and
analytical modelling approach
• Calculates electrical & electromagnetic
performance
• Coupled solution with the thermal model
• Automatically set-up calculations for
different performance tests.
Motor-CAD electromagnetic module
Radial winding pattern Induction machine equivalent circuit
Fourier analysis of the voltage
waveform
Linear winding layout
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Motor-CAD Therm
• Industry standard tool for thermal analysis ofelectric machines with over 20 years ofinbuilt experience.
• Calculates temperature of the motorcomponents in steady-state and transientoperating conditions.
• Enables accurate modelling of thermalbehaviour within seconds of calculation.
• Enables understanding of main heat transferpaths and opportunities to significantlyimprove output.
• Allows iteration and full exploration of thedesign space, alongside electromagneticanalysis; ensuring optimal design decisions.
Motor-CAD thermal module
Visualisation of oil
spray cooling
Thermal network
Radial temperature
distribution
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Motor-CAD Therm
Cooling types
Fan cooled machine
with cowling
Water jacket with
axial channels
Through ventilation
with radial ducts
• Totally enclosed non-ventilated
• Totally enclosed fan cooled
• Through ventilation
• Totally enclosed with internal circulating air
• Open end-shield cooling
• Water jackets
• Submersible cooling
• Wet rotor & wet stator cooling
• Spray cooling (oil on end-windings)
• Direct conductor cooling
Manufacturing data
• Thermal modelling of electric machine can be
challenging as thermal behaviour is significantly affected
by manufacturing aspects.
• Examples of manufacturing uncertainties that affect
temperature rise:
– Quality of effective interface between stator
and housing
– How well the winding is impregnated or potted
• Experience is built into the software to assist users in
selecting appropriate values.
• Losses, efficiency and energy usage can be calculatedacross any duty cycle.
• The behavior of the machine is solved with the thermalmodel to give temperature rise against time.
• The variation of losses and magnet flux (torque/amp)with temperature is accounted for.
• This enables engineers to design a machine with
minimum size/cost and optimise the design for
maximum cycle efficiency.
Duty Cycle Analysis
Motor/Generator:
Temperature Vs Time
Motor/Generator: Time vs Torque vs Speed
Co-solved electromagnetic and
thermal behavior over cycle
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Motor-CAD Lab Efficiency map
Calculated peak and continuous torque/speedcurves
Torque is limited on maximum
winding temperature
Torque is limited on maximum
rotor/magnet temperature
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Motor-CAD Mechanical
• FE solution based
• Very fast – solves within a
couple of seconds
• Template or DXF import
options available
• Enables engineers to considerMagnetic and Mechanical performancetrade-off in design optimisation
Stress Analysis for High-Speed RotorsVon Mises Stress in IPM rotor at maximum speed
Motor-CAD EMag – Maxwell Links (2D, 3D)
Automatic link
Electronics Desktop(Maxwell)
• Geometry, winding, drive,symmetry, boundaryconditions and materials areall transferred from Motor-CAD to Maxwell
• Transferred model is readyto simulate.
MotorCAD
ANSYS Motor-CAD – optiSlang
• Enabling comprehensive design space exploration
• Design candidates evaluated against full design specification
• Multi-physics, multi-objective optimisation
CUSTOMER CASES
MAXWELL
Borg Warner
MAXWELL
Pain
Solution
$170,000 5x Motor-CAD licenses in 2016
$400,000 total revenue from growth and TECs 2016-2019
Competition
Existing: Internal tools + SPEED
There are no equivalents to Motor-CAD multi-physics solution on the market.
Account Manager n/a
ACE Engineersn/a
Metric
• Initial introductory meeting to present Motor-CAD solution• Evaluation support• Internal seminars and training to promote growth in usage.
Activity
Takeaway: Replacing internal electric motor design tools is an excellent opportunity. Motor-CAD solution can generate significant revenue.
• Existing tools supporting electric machine design - mixture of internally developed and external software. Limitations in terms of capability, accuracy and support.
BorgWarner Success Story
• More competitive designs – increased design capability• Reduction in design iterations – increased accuracy from design tools• Reduced risk of non-conformance to customer specification.• Risk mitigation against vulnerability to loss of current employee expertise
MTS
MAXWELL
Displacement example - MTS
• Develops high performance electric machines used in motorsport including top Formula_e and F1 teams
• Previously used Jmag exclusively
• We placed Motor-CAD in 2016. Replacing SPEED.
• Customer found they naturally increased the use of Motor-CAD in the workflow replacing Jmag as the tool for design space exploration and iterative what-if analysis
• Motivations for this have been clearly stated as the automated links with Motor-CAD
• Combined solution can displace Jmag.
• Motor-CAD can be used a non-threating initial footprint to be sold alongside Jmag.
• They have also stated that the link will enable increased Maxwell usage in MTS by allowing some engineers to broaden their simulation capabilities.
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Pain
Solution
Motor-CAD licenses initially –followed by Motor-CAD + Maxwell deal in 2020.
Competition SPEED + JMag
Account Manager
ACE Engineers
Metric
• Placed initial Motor-CAD license to replace SPEED in 2016
• Motor-CAD usage in workflow grew and took a more dominant role,
supported by training and attendance at Motor-CAD conferences.
• Decision to replace JMag with Maxwell in 2020 due to productivity
advantages with tool couplings.
Activity
Takeaway: Motor-CAD can be placed alongside competitors to
Maxwell without requiring a significant investment in changing the
workflow. This will then create significant opportunities for Maxwell
as Motor-CAD usage grows.
• Limitations of capability in existing tool SPEED. Lack of support and
developments.
MTS Success Story
• Drive cycle analysis capability
• Fast multi-physics front end design tool
• Accurate analysis