Elect ectric ic Machin ine e Design ign Stef efan n Holst, - - PowerPoint PPT Presentation

The use of Simulation mulation in Elect ectric ic Machin ine e Design ign Stef efan n Holst, lst, CD CD-adapco dapco

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g power r requi uire reme ments nts in gene neral al In batteries eries, , overhe heati ting ng leads ds to fa faster aging A jo A joint nt si simulation ulation approach ach allows ws to si simulat ulate e the e coup uple led electr ctric ic and thermal ermal problem blem early y on in the e design sign process cess

Motiv ivati ation

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CD CD-adapco’s Purpose

3 CD CD-adapco’s purpose is to inspire innovation while reducing customer costs ts through ugh the e app pplicati tion

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nginee eering ng simu mulati tion

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CD CD-ada adapc pco:

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Our independence breeds engineering success

• Largest independent CAE/CFD provider
• Heavily invest in employees
• Continuously invest in development of new technology

Our purpose is to ensure the customer’s success through the use of engineering simulation

• Enable & inspire innovation
• Reduce engineering time & costs

We provide successful engineering simulation solutions

• Software products like STAR-CCM+ that are accurate, efficient, and easy to use
• Flow, Thermal and Stress simulation in a single tool.
• Local dedicated support
• Engineering services: technology transfer, burst engineering resources,

custom software tools

We are a growing and successful engineering simulation company

• 20% growth in FY2011 global software sales
• $138m End User Spend in FY2011
• >700 employees in ~25 offices
• 40% of employees involved in Research and Development activities
• >8000 users worldwide

SPEED’s own thermal capability consists of simplified circuit models

– Good for a first shot – Circuit model allows for quick analysis of duty cycle simulations

Ef Efficien iency cy requi uire reme ments, nts, space e and d weight ight restr tric icti tions

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d to more re compl plex x machi chine ne and machine hine enclos closure ure designs igns

– Identifying hot spots becomes tricky – STAR-CCM+ can show its strength in these models

User r should ld bene nefit t as muc uch h as possible ible from

• m the

e work done ne in SPEE EED

– Import geometry – Import distribution of heat loads  electromagnetic losses – Future: coupled EMAG and thermal analysis in a single tool

Overvie view

SPEE EED is the e leading ding design esign softw tware are for

• r elect

lectri ric c machi chine nes

– Detailed analytical analysis with finite-element links or finite-embedded solver for

• motors, generators and alternators
• including inverters and other electronic controls

Special cialize ized d tool

• ls per mot
• tor
• r type

e imp mprove e design ign efficie iciency ncy

– PC-BDC for brushless permanent magnet and wound-field AC synchronous – PC-IMD for induction machines – PC-SRD for switched reluctance – PC-DCM for direct current (PM) – PC-WFC for wound field and PM commut.

Early rly to mid stages ages of machine ine design ign

SP SPEED ED – The

e desi sign gn process cess

1 2 3 4 5 6 7 8

Equiv ivalent alent circuit uit meth ethods

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Inst stantane ntaneous

• us results

ts with th todays ys comput puters As Assumpti tion

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s on flux ux path and mathe hematical tical mode dels s give e estima imates es on circui uit t parame meter r

– Inter phase dependence is difficult to incorporate (SRM) – Modeling assumptions have certain validity range only

How How to keep ep computa putati tiona

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l sp speed eed but ut extend end applicabi ability lity

– Use 2D/3D FEA to calibrate, but limit to as to few key simulation conditions

SP SPEED ED in use: GoFE FER

Go Go to Finite-Elements and Return … or use the embedded FE-solver directly (PC-BDC) Two FE runs only

Data a transf ansfer er to STAR-CC CCM+

The e B-fiel ield d variation ion allows ws iron n loss ss estimati stimation

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– GoFER of 72 rotor positions /elec. revolution – Modified Steinmetz method in SPEED applies also to non sinusoidal currents – Element Table tool to view and export cell-wise values

Simulat ation ion goal: l: steady ady state e temperatu peratures res A w A water er cooled

• led casing

ng and end d windin nding g regions ions are added ded to the e SPEE EED model

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imp mpor

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– Coolant is induced at 50 °C, at a volume flow rate of 1 l/s

Iden entify tify inter erface ces where ere thermal ermal resis istan tance ces s model

• del neglec

glected d fine e detail etails

– slot liner, stator to housing contact imperfections, magnet to rotor contact

Rot

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ation ion is modeled

• deled with

h a movi ving ng referer erernce ce approa

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ch

– Source to the momentum equation in a domain enclosing the rotor and shaft parts

Therm rmal l modell ellin ing g in STAR AR-CCM+ CCM+

Example taken from the paper “STAR-CCM+ and SPEED for electric machine cooling analysis”, CWIEME 2012, Berlin

Therm rmal l modell ellin ing in n STAR AR-CCM+ CCM+

Resolving solving each ch wire e is too

• cost

stly

– Model winding as bulk region – Gaps between wires and wire insulation are accounted for using anisotropic material properties – Local wire orientation is interpolated from easily selectable edge orientation – Off directional thermal conductivities is tuned to resemble spread between mean and max winding temperatures

Ai Air and cool

• lant

ant flo low w is solved ed us using g standar ndard d tur urbulence lence mode del set etti ting ngs s in STAR AR-CC CCM+ M+

Resu sults lts

Using ng the e STAR AR-CC CCM+ M+ coup upled led so solver er in the e flow w converge ges s within hin 120 itera rati tions

• ns

The e tempera perature ture distribution ribution clearl rly y indica icates that t the e windin ndings gs closer er to the e cool

• lant

ant out utlet t are un under der higher her therm rmal l stress ess

1000 rpm 6000 rpm

SP SPEED ED and nd STAR-CCM CM+ – the combin

mbined ed workfl flow for Elec ectr tric ical al Mach chin ines es

Initial design with SPEED PC-FEA: Loss table calculation Reading the SPEED geometry and the loss distribution Running the final advanced thermal calculation.

Temperatures impact life time, reliability, cost & size

STAR-CCM+ CM+ v8.02 coup uples les with h 1D co D codes

– AMESIM – Wave – OLGA – And via scripting also to Matlab/Simulink

Applicati ications

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– Full vehicle simulation

• Drive cycle simulations
• Control of the battery

– Prevent excessive loading on high temperature

E-mo motor

• r simulations

mulations

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Applications  Hydraulics  IC engines  Electro-magnetic systems  Battery control

Start simulation

• Open port

Macro connects to Simulink port Specify reports Store list of reports Specify input:

• field functions
• time step size

Run Step

• Send reports

Update circuit time step

Protocol col Design ign

……

Matlab lab/Si /Simulin ulink k

Thank k you