Motor-CAD Links to SPEED Mircea Popescu & Dave Staton Motor - - PowerPoint PPT Presentation
Motor-CAD Links to SPEED Mircea Popescu & Dave Staton Motor Design Ltd March 2012 Topics Motor Design Ltd Motor-CAD software and other design tools marketed by MDL The SPEED Thermal Models SPEED and Motor-CAD together
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Electric Machines
simulation of any device
process easier for the user (link to SPEED software):
design for full torque/speed envelope rather than a single torque/speed
without having to write a computer script (draw a flow diagram instead)
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the worlds leading analytical software package for the design of electric motors (with integrated FEA) unique analytical software package for the thermal analysis of electric motors SPEED & Motor-CAD’s analytical based algorithms give instantaneous calculation speeds and allow 'what-if' analysis in real time finite element software well adapted for accurate electromagnetic simulation of electric motors system simulator developed for the calculation of drives and mechatronic systems
– thermal library allows thermal analysis of almost any device with mixed electrical/mechanical/thermal simulation
now have STAR-CCM+ for advanced thermal analysis using CFD
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and calculate steady state or transient temperatures
calculated automatically
specialists
speeds
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– thermal resistances rather than electrical resistances – power sources rather than current sources (losses) – thermal capacitances rather than electrical capacitors – nodal temperatures rather than voltages – power flow through resistances rather than current
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Motor-CAD includes proven models for an extensive range of cooling types
– Natural Convection (TENV)
– Forced Convection – (TEFC)
– Through Ventilation
– Open end-shield cooling – Water Jackets
– Submersible cooling – Wet Rotor & Wet Stator cooling – Spray Cooling – Direct conductor cooling
– Conduction
– Radiation
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– the designer selected a housing type that is appropriate for the cooling type to be used and then optimizes the dimensions, e.g. axial fin dimensions and spacing for a TEFC machine
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–aerospace, automotive, industrial, renewable, transport and university sectors:
ABB
Alarko Carrier
Alstom Ecotecnica
Ametek
BAE Systems
Bombardier Transportation
Bosch
BMW
Brose
Caterpillar
Continental
Cummins
Crompton Greaves
Daewoo
Daimler
Dana
Danaher Motion
Delphi Corporation
Otis Elevators
Parker Hannifin
Peugeot
Porsche
Precilec
QinetiQ
Renault
Rolls Royce
SEM
Siemens
Thales
Valeo
Vestas Wind Systems
Visteon
Volvo
VW
WEG
Whirlpool
Dupont
Eaton
Esterline
Ford
GE Energy
GE Transportaion
General Dynamics
General Motors
Goodrich Aerospace
Grundfos
Hewlett Packard
Johnson Electric
Kollmorgen
Liebherr Aerospace
Lockhead Martin
Magna
Magneti Marelli
Moog
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– very simple thermal network models built into software but require calibration
– losses are critically dependent on temperature – temperatures are critically dependent on loss
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– direct access to physical input parameters such as “Tooth Width”, “Airgap”, “Liner Thickness”, “Turns Per Coil”, “Liner Thermal Conductivity”, etc. – direct access to physical output parameters such as “Shaft Torque”, “Copper Loss”, “Winding Average Temperature”, “Winding Hotspot Temperature”, “Magnet Temperature”, etc.
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Design Aims Possible Solutions Specialist Motor Design Packages [Electomagnetic & Thermal]
e.g. Electromagnetic - Speed Thermal - Motor-CAD
Prototypes & Test Numerical Analysis [Electomagnetic & Thermal]
e.g. Electromagnetic - Flux-2d & Flux-3d Thermal - CFD
– electromagnetic and thermal
– Geometry – Losses – Temperatures
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– This process assumes the user has some test data or can be done automatically using Motor-CAD
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– import/export geometry (with choices of what data to transfer) – import losses – export temperatures
– loss function of temperature and temperature function of loss
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– geometry, winding and losses
dimensional details not available in SPEED are given reasonable values – housing, endcaps, bearings, etc.
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– default materials can often be used initially with fine selection later
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– Can fine tune certain dimensional parameters that have no direct
equivalent in PC-BDC, housing type, bearings etc.
– intelligent geometry scaling makes sure all parts fit the size of
machine under consideration
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– Imported wire size and turns correctly – Colours represent amounts of copper (yellow) and insulation (green)
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exist and what can be done to make the machine cooler
– Materials, mounting, improved impregnation, interface gaps, etc.
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temperatures so need to check that steady state reached (200min)
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– Warning given if PC-BDC not reached steady state
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– Should plot magnet and winding average temperature
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predictions of temperatures (3 times current with 50% duty cycle, 10 min):
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– Warning given if PC-BDC not reached steady state
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– Easy to set these temperatures from Motor-CAD (iterative model losses/temperatures available)
Motor-CAD
– Can then change load in SPEED and calculate losses with more accuracy than Fixed temperature model – Assumes all thermal quantities in the SPEED model are not functions of rotational speed & temperature – Need to re-calibrate if change design
– always calculates a transient and so must ensure that time period is long enough if steady- state results required – only able to set up limited duty cycle waveforms with Hot10 – Must calibrate the Hot10 model each time a change is made to the design otherwise invalid temperature and so overall performance predictions often result – Many parameters to calibrate – Assumes all thermal quantities in the Hot10 model are not functions of rotational speed & temperature – Hot10 model can be unstable
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