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

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Apr 09, 2023 175 likes •344 views

1 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.

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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

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VIB VIBRA RATE TEC C IN IN A A WIN WINK

NVH NVH & str structu tural r l reli liabil ility ity

Railway Automotive Aeronautic Defense Oil & Gas Industry

ALTAIR users meeting – October 2019

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VIB VIBRA RATE TEC C IN IN A A WIN WINK

NVH NVH & str structu tural r l reli liabil ility ity

ALTAIR users meeting – October 2019

Vibratec evolves towards better services, more efficient and fitting our customers’ expectations Multiphysical design

Electromagnetic
Gear noise
Multi body
Non linear simulations

Components characterization

Acoustic Power
Vibration levels
Transmission error
Blocked force

NVH & reliability expertise

Diagnosis/TPA
Support to design
Benchmarking
Trainings

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VIB VIBRA RATE TEC C AL ALTAIR AIR CO COLL LLAB ABOR ORATION TION

No Noise ise of E-ma machine ine

2010-2013 : R & D project AVELEC
Development & validation of a computation method
Application to RENAULT first E-powertrain
2019-2021 : R & D project E-Silence
Topology optimisation of E-machine
Uncertainties, dispersion of noise
Low noise solutions
2019 : Development of a dedicated software under ALTAIR’s platform (FLUX)

ALTAIR users meeting – October 2019

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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

Power supply Flux density and electromagnetic excitation Structure dynamic response Noise radiation and vibration transmission

Some examples of noise:

ALTAIR users meeting – October 2019

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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

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Current waveform Rotor/stator design Magnetic excitations Modal basis Operationnal vibration Excitations Structure Response 1 2 3

ALTAIR users meeting – October 2019

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RESUL RESULTS TS & V & VALID ALIDATION TION (1/2) (1/2)

Auto tomo motiv tive tr traction tion mot motor

Engine Order 44

Speed [rpm] Acceleration [m/s²]

Stator mean squared acceleration

10 dB

Engine Order 44

ALTAIR users meeting – October 2019

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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 Objective :

find a EM design that minimizes the vibration and/or

noise levels of the machine for given operating conditions (speed(s), current)

Quantity to minimize:

torque ripple,
sound power level,
…

Constraints:

keep an acceptable torque (e.g. less than 2%

compared to the torque obtained for the initial design)

Structural reliability (internal stress due to

centrifugal forces)

Electromagnetic Simulation

Electromagnetic mesh

Mapping tool

Electromagnetic excitation

Dynamic simulation (3D Finite Element Method)

Structural mesh Dynamic excitation

Acoustic simulation (FEM or BEM or analytical)

Vibration velocity

Acoustic power

Optimisation algorithm

Geometrical parameters

ALTAIR users meeting – October 2019

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TP TPOL OLOG OGY OPT Y OPTIMI IMIZA ZATION TION

WRSM WRSM ma machine ine

POLERAD POLEWID EDGEGAP BETAC BETAM

ALTAIR users meeting – October 2019

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EL ELECTRIC ECTRICAL AL MA MACH CHIN INE E DESIGN DESIGN

CAS CASE E ST STUD UDY Y #1 #1 : : EM EM to topo polog logy op

ptimi

timiza zation tion Significant gain in terms of sound power level by playing on the topology of the EM

Mean Torque Torque ripple RPM  Rotor angle 

Constraints

ALTAIR users meeting – October 2019

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EL ELECTRIC ECTRICAL AL MA MACH CHIN INE E DESIGN DESIGN

2018 : our first industrial case validation
Minimal Gain : 10 dB
Performance are in the specifications
Robustness is checked
Development is going on :
Robustness integration
Reliability integration
Optimization of :
Power supply
Structure and resin
Vehicle integration

TEST Result

H48

ALTAIR users meeting – October 2019

CASE STUDY #1 :

CAS CASE E ST STUD UDY Y #2 #2 : : EM EM to topo polog logy op

ptimi

timiza zation tion, , PMSM mac machine hine

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EL ELECTRIC ECTRICAL AL MA MACH CHIN INE E DESIGN DESIGN

ALTAIR users meeting – October 2019

CAS CASE E ST STUD UDY Y #2 #2 : : EM EM to topo polog logy op

ptimi

timiza zation tion

13 WOT

Engine order 8 Engine order 48 Engine order 96 Engine order 24

Initial design Optimal design

10dB 10dB 10dB 10dB

Initial design Optimal design Initial design Optimal design Initial design Optimal design

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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
Electromagnetic-Dynamic-Acoustic weak coupling
Several validation cases
Wide optimization possibilities : electromagnetic design optimisation
No complex counter measure
No additional mass
No additional cost
The earlier in the design phase, the better…

ALTAIR users meeting – October 2019