1 AGEND GENDA No Noise ise of E-ma machine ine VIBRATEC in a - PowerPoint PPT Presentation

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AGEND GENDA No Noise ise of E-ma machine ine • VIBRATEC in a wink • Context of ALTAIR and VIBRATEC collaboration • Physical phenomena at the origin of Noise and Vibration • Simulation process • Numerical results and validation vs. experiments • Electric design optimization ALTAIR users meeting – October 2019 2

VIB VIBRA RATE TEC C IN IN A A WIN WINK Defense NVH NVH & str structu tural r l reli liabil ility ity Aeronautic Industry Railway Oil & Gas Automotive ALTAIR users meeting – October 2019 3

VIB VIBRA RATE TEC C IN IN A A WIN WINK NVH NVH & str structu tural r l reli liabil ility ity Vibratec evolves towards better services, more efficient and fitting our customers’ expectations Components characterization Multiphysical design NVH & reliability expertise • Acoustic Power • Electromagnetic • Diagnosis/TPA • Vibration levels • Gear noise • Support to design • Transmission error • Multi body • Benchmarking • Blocked force • Non linear simulations • Trainings ALTAIR users meeting – October 2019 4

VIB VIBRA RATE TEC C AL ALTAIR AIR CO COLL LLAB ABOR ORATION TION Noise No ise of E-ma machine ine  2010-2013 : R & D project AVELEC o Development & validation of a computation method o Application to RENAULT first E-powertrain  2019-2021 : R & D project E-Silence o Topology optimisation of E-machine o Uncertainties, dispersion of noise o Low noise solutions  2019 : Development of a dedicated software under ALTAIR’s platform (FLUX) ALTAIR users meeting – October 2019 5

NO NOISE ISE AN AND D VIB VIBRA RATION TION GENERA GENERATION TION Phys Physica ical l phenoma ma at t th the origin rigin of No Noise ise and Vibr ibration tion Flux density and Structure dynamic Noise radiation and electromagnetic Power supply response vibration transmission excitation Some examples of noise: ALTAIR users meeting – October 2019 6

NO NOISE ISE AN AND D VIB VIBRA RATION TION GENERA GENERATION TION Phys Physica ical l phenoma ma at t th the origin rigin of No Noise ise and Vibr ibration tion 1 Response 2 Excitations Structure 3 Current waveform X Operationnal vibration Modal basis Magnetic excitations Rotor/stator design ALTAIR users meeting – October 2019 7

RESUL RESULTS TS & V & VALID ALIDATION TION (1/2) (1/2) Auto tomo motiv tive tr traction tion mot motor Engine Order 44  Stator mean squared acceleration Engine Order 44 Acceleration [m/s²] 10 dB Speed [rpm] ALTAIR users meeting – October 2019 8

EL ELECTRIC ECTRICAL AL MA MACH CHIN INE E DESIGN DESIGN CASE CASE ST STUD UDY Y #2 #2 : : EM EM to topolog logy optimiza timization tion Geometrical parameters Objective :  find a EM design that minimizes the vibration and/or noise levels of the machine for given operating Electromagnetic Simulation conditions (speed(s), current) Electromagnetic Electromagnetic mesh Quantity to minimize: excitation Optimisation  torque ripple, Mapping tool algorithm  sound power level,  … Dynamic Structural excitation mesh Constraints: Dynamic simulation  (3D Finite Element Method) keep an acceptable torque (e.g. less than 2% compared to the torque obtained for the initial Vibration design) velocity  Structural reliability (internal stress due to Acoustic simulation centrifugal forces) (FEM or BEM or analytical)  … Acoustic power ALTAIR users meeting – October 2019 9

TP TPOL OLOG OGY OPT Y OPTIMI IMIZA ZATION TION WRSM ma WRSM machine ine EDGEGAP POLERAD POLEWID BETAC BETAM ALTAIR users meeting – October 2019 10

EL ELECTRIC ECTRICAL AL MA MACH CHIN INE E DESIGN DESIGN Constraints CAS CASE E ST STUD UDY Y #1 #1 : : EM EM to topo polog logy op optimi timiza zation tion Mean Torque RPM  Torque ripple Rotor angle  Significant gain in terms of sound power level by playing on the topology of the EM ALTAIR users meeting – October 2019 11

EL ELECTRIC ECTRICAL AL MA MACH CHIN INE E DESIGN DESIGN CAS CASE E ST STUD UDY Y #2 #2 : : EM EM to topo polog logy op optimi timiza zation tion, , PMSM mac machine hine o 2018 : our first industrial case validation  Minimal Gain : 10 dB  Performance are in the specifications TEST Result  Robustness is checked H48 CASE STUDY #1 : o Development is going on :  Robustness integration  Reliability integration  Optimization of : Power supply • • Structure and resin Vehicle integration • ALTAIR users meeting – October 2019 12

EL ELECTRIC ECTRICAL AL MA MACH CHIN INE E DESIGN DESIGN CAS CASE E ST STUD UDY Y #2 #2 : : EM EM to topo polog logy op optimi timiza zation tion WOT Engine order 8 Engine order 48 10dB Initial design Initial design 10dB Optimal design Optimal design Engine order 24 Engine order 96 10dB Initial design Initial design Optimal design 10dB Optimal design ALTAIR users meeting – October 2019 13 13

CO CONC NCLUSIO USION A A digita igital l twin twin to to analyz yze operation tional data tas s and to to predict ict th the rema emaining ining li lifetime time  Noise of e-machines: new field of expertise  Powerfull multiphysical simulation methodology o Electromagnetic-Dynamic-Acoustic weak coupling o Several validation cases  Wide optimization possibilities : electromagnetic design optimisation o No complex counter measure o No additional mass o No additional cost  The earlier in the design phase, the better … ALTAIR users meeting – October 2019 14

CO CONC NCLUSIO USION No Noise ise of E-Mac Machine ines Thank you for your attention ! Dr. Pascal BOUVET / pascal.bouvet@vibratec.fr ALTAIR users meeting – October 2019 15