1 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
New Electromagnetic-Thermal Coupled Analyses for Electrical Machine Design
Marius Rosu, PhD EM Lead Product Manager, ANSYS Inc.
2 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Manoj Nagulapally - ANSYS CFD Expert, USA
Mike Slack - ANSYS CFD Expert, UK
Yang Hu - ANSYS Electromagnetics, USA
Eddie Chong - MDL CFD Expert, UK
Acknowledgments
3 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Integrated Motor Design Flow
Magnetic and Thermal Sizing Solution
• Case Study - PM Machine Design
Hybrid CFD Solution
• Case Study – IPM Motor Design
Electromagnetic - CFD Coupled Solution
• Case Study - Traction EV Motor Design
Outline
4 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Motor Design Flow
Initial Design Electromagnetic Components Stress/Acoustic Temperature
Workbench System wide optimization using CAD parameters
0-D System
5 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Integrated Motor Design Flow
Magnetic and Thermal Sizing Solution
• Case Study - PM Machine Design
Hybrid CFD Solution
• Case Study – IPM Motor Design
Electromagnetic - CFD Coupled Solution
• Case Study - Traction EV Motor Design
Outline
6 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
ANSYS Inc. and Motor Design Ltd. Collaborated to build an innovative new design flow that leverages, - ANSYS expertise in magnetic sizing of electric machines - Motor Design expertise in thermal sizing of electric machines
7 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
First-Pass Integration with ANSYS Software
RMxprt Motor Design
ANSYS Mechanical
Thermal/Stress
ANSYS CFD
Maxwell 2-D/3-D Electromagnetics
Simplorer System Design
PP := 6
ICA:
A
A
A
GAIN
A
A
A
GAIN
A
JPMSYNCIA
IB
IC
Torque JPMSYNCIA
IB
IC
TorqueD2D
Motor-CAD
Thermal
+
Magnetic and Thermal Sizing
8 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Magnetic and Thermal Design Sizing Solution • Template-based electrical machine
design
• Fast analytical calculations for popular electric machine topologies
• One-click setup for Maxwell 2D and 3D finite element Solutions
• Network analysis dedicated to thermal analysis
• Heat transfer data calculated automatically
• Detailed cooling systems & facilitates optimisation
RMxprt
Motor-CAD
9 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
RMxprt - Magnetic Sizing
10 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
RMxprt - Magnetic Sizing Electric Machines Configurations
PM Rotor Topologies
Slot Editor
Winding Editor
11 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Housing in RMxprt – New Capability Machine
– Stator – Rotor – Shaft – Housing
– Fin – Duct – Front Cap – Rear Cap – Foot – Flange
Overall Width
Cutout Depth
Fin Thickness
Inner Diameter
Flan
ge
Diam
eter
Plat
e He
ight
Plate Thickness
Flange Thickness
Base Thickness
Base Width
Foot Width Palm Width
Shaft Height Foot Distance
Palm Height
Length Extension
Cap Thickness Ho
lder
Dia
met
er
Bear
ing
Diam
eter
Shaft Diameter
Bearing Thickness
Out
er D
iam
eter
12 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
New UDP for Thermal Field Analysis
Housing – Four different profiles – Six different fin types – Three different duct types
EndCaps
13 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Motor-CAD – Thermal Sizing
Includes proven models for an extensive range of cooling types: TENV: Totally enclosed non-
ventilated TEFC: Totally enclosed fan
cooled Through Ventilation TE with Internal Circulating Air Open end-shield cooling Water Jackets Submersible cooling Wet Rotor & Wet Stator cooling Spray Cooling Direct conductor cooling
14 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Motor-CAD – Thermal Analysis
• Analytical lumped circuit analysis • Combined Thermal and Flow network
analyses • Steady state thermal analysis • Complex transient duty cycle analysis
15 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Motor-CAD Integrated Thermal FEA Solver
Motor-CAD fully integrated FEA thermal solver allows fast calibration of analytical model giving best compromise of accuracy & calculation speed
16 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Case Study - PM Machine Design
• Electromagnetic performance calculated in RMxprt • Default housing in RMxprt has axial fins which are suitable for TEFC cooling • Geometry and power losses are exported to Motor-CAD
RMxprt - Motor CAD
17 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Case Study - PM Machine Design
• Winding also exported from RMxprt • Motor-CAD updates winding to account for
wire size available, enamel on wire and slot liner available
RMxprt - Motor CAD
18 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Case Study - PM Machine Design
Steady-State Thermal - Instantaneous simulation
Repetitive Duty Cycle Analysis - Rapid simulation
19 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Case Study - PM Machine Design
Robust Design Analysis on Thermal Sizing - Parametric analysis - Sensitivity analysis
Initial Design Selected Design
20 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Integrated Motor Design Flow
Magnetic and Thermal Sizing Solution
• Case Study - PM Machine Design
Hybrid CFD Solution
• Case Study – IPM Motor Design
Electromagnetic - CFD Coupled Solution
• Case Study - Traction EV Motor Design
Outline
21 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Motor-CAD Thermal Network
Equivalent thermal network of a machine can be generated based on the machine information (geometry, materials, cooling types, heat sources, etc.)
Convective heat transfer is predicted using heat transfer correlations
The accuracy of the convection is only as good as the appropriateness and validity of the correlations used in the calculation, e.g. flow over fins, housing water jacket, etc.
22 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Hybrid Model : CFD Domain Definition Motor – Thermal-Flow Network Equivalence
Motor-CAD thermal network is imported into ANSYS Icepak
ANSYS Icepak network replaces the thermal resistances between the housing and ambient with a CFD domain
Inside the housing, the machine is modelled using Motor-CAD thermal network, whereas the convective heat transfer outside the housing is modelled using an Icepak CFD domain
The thermal network and the CFD domain are coupled together through multi-faceted cylinder housing interfaces
Thermal-Net
Flow-Net
For the current application only thermal network is used
23 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Detailed and Hybrid Models: Comparison
Detailed Model : 2M elements Network Model : 67k elements
3D Natural Convection Simulation on Hybrid Model • Turbulent flow model • Radiative heat transfer model • Fully parallelized solver • Converged CFD solution in ~ 2 minutes
24 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Hybrid Model: CFD Simulation Results
Flow tracks around network Nodal temperature report
25 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Integrated Motor Design Flow
Magnetic and Thermal Sizing Solution
• Case Study - PM Machine Design
Hybrid CFD Solution
• Case Study – IPM Motor Design
Electromagnetic - CFD Coupled Solution
• Case Study - Traction EV Motor Design
Outline
26 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
More Extensive FEA/CFD
Automated ANSYS couplings speed up creation of 2D/3D FEA and CFD models to make more detailed calculations • 3D electromagnetic effects • CFD to check/calibrate flow
calculations • AC loss in winding
SpaceClaim
Maxwell
Fluent
Motor-CAD
Icepak
27 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Electromagnetic to CFD
• RMxprt creates complete Maxwell 3D model with housing
• Icepak account for air flow and mechanical motion on CFD domain
Temperature Profile
Icepak
Icepak
Maxwell
28 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Modeling Water Jacket Cooling Channels
Path Lines Static Pressure
Fluent
29 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Modeling Water Jacket Cooling Channels
Temperature Profile
Distribution of coolant using different channel configurations Fluent
30 © 2013 ANSYS, Inc. October 2, 2014 ANSYS Confidential
Comprehensive Electromagnetic and Thermal coupled design concepts are considered at different level of design adoption
• Sizing design - Rapid Virtual Prototyping where thousands of “what if’s” can be performed in seconds;
• Hybrid design - Fast investigation of various cooling systems using thermal network coupled with CFD domain
• Physics-based design - Electromagnetic-CFD coupled solution for detailed analysis
Summary
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