Software Solutio ions for the Desig ign and Simula latio ion of - - PowerPoint PPT Presentation

Software Solutio ions for the Desig ign and Simula latio ion of Electric ic Machines

• Dr. Markus

us Anders, CD-adapco

Software for Electric Machine Design and Simulation:

• About SPEED
• SPEED & JMAG
• SPEED & STAR-CCM+, 2D EMAG
• SPEED & HEEDS: An optimization case
• SPEED & STAR-CCM+, Thermal: Workflow
• STAR-CCM+, Thermal: Link with other software suppliers
• STAR-CCM+ & JMAG: Example

Agenda

About SPEED

SPEED is the leading initial design software for electric machines

• Detailed analytical analysis with finite-element links or finite-embedded solver for
• motors, generators and alternators
• including inverters and

GoFER using PC-FEA

• ther electronic controls.
• The embedded FE solver (using PC-FEA)
• is a unique capability,
• enables our customers to do things SPEED could not
• therwise do and
• improves the accuracy of SPEED by a substantial margin.
• The analytic approach provides nearly

instantaneously results (in seconds/minutes).

• Development started early 1980’s on PC’s under MS-DOS platform using Pascal as

the programming language at the SPEEDLab, University of Glasgow by Prof. TJE Miller.

About SPEED

• Over 1000 corporate accounts worldwide
• 6 main machine programs for
• Synchronous machines:

PC-BDC,

• Induction machines:

PC-IMD,

• Switched reluctance machines:

PC-SRD,

• Brushed PM-DC machines:

PC-DCM,

• Wound-field commutator machines:

PC-WFC and

• Axial flux machines:

PC-AXM

• Fully scriptable (ActiveX)
• Can link to other FE programs, such as
• JMAG
• Flux
• Opera
• …

• SPEED models can be easily imported into JMAG by using the

GoFER Run Option “Other FEA links …”.

SPEED D & J JMAG

• The types that are currently

supported are − synchronous machines (through PC-BDC) and − induction machines (through PC-IMD).

http://www.jmag-international.com/

SPEED D & S STAR-CCM+

STAR-CCM+ has been added as well to the list of Run options in the BDC GoFER dialog:

– Single-load-point – Bgap distribution (OC) – Btooth waveform (OC) – Cogging torque – i-psi calculation – i-psi Polygon

PC- FEA

• The GoFER’s using STAR-CCM+ makes arbitrary machine geometry manipulation

very easy to fit the actual shape by using the incorporated CAD-modeller in STAR- CCM+ resulting in improved accuracy of the model.

SPEED D & S STAR-CCM+

SPEED’s Bgap GoFER with STAR-CCM+

SPEED

SPEED D & H HEEDS

Multi-disciplinary Design Optimization

Parallel Plot showing design trends among designs evaluated during an optimization.

The main features: – Multi-disciplinary, multi-objective parametric design

• ptimization using SHERPA

– Automated Design of Experiments – Sensitivity studies – Robustness and reliability assessments – Design Sweep (post processing)

• Create a variety of plots and tables
• Best illustrate relationships among

variables and design goals

• Multiple search methods

simultaneously,

• A combination of global and local

search methods,

• No tunable parameters; all

parameters are automatically adjusted in an adaptive manner,

• Adaptive

Automated by scripting

SPEED D & H HEEDS – Very simple optimization example

for minimum cogging torque and magnet volume

Concept A Optimized Design: 94% reduction in cogging torque 52% reduction in magnet volume Concept B Optimized Design: 93% reduction in cogging torque 59% reduction in magnet volume Baseline Design

• Appr. 2000 calc., 3 hours

Feasible Infeasible

SPEED D & H HEEDS – Desig ign Exploratio ion

Using the US06 Drive Cycle

Results Motor Design Parameters SHERPA

Geometry Motor Efficiency

Note: Only FEASIBLE Design Concepts are Displayed

STAR-CCM+ is a powerful, all-in-one tool that combines:

– Ease of use, – All-in-one software package, – Automatic meshing, – Extensive modelling capabilities, – Powerful post-processing.

Developed since 2004:

– Uses the latest numeric and software technologies. – Designed from the outset to handle very large models (100M+ cells). – Full process integration: CAD to CAE in one package. – Rapid development cycle: new releases every for months – Started originally as a CFD software package

STAR-CCM+: General l 3-D

Multi-physics & Multi-purpose software

CAD STAR-CCM+ Report

Integrated engineering solution for solving multidisciplinary problems

Geometry Surface Preparation Analyses Meshing CAE Integration Multidisciplinary

STAR-CCM+: General l 3-D

Multiphysics & Multipurpose software

For electrical machines:

– CHT (Conjugate Heat Transfer including Conduction, Convection and Radiation) – Windage losses (e.g. surface PM, no rotor sleeve or Switched Reluctance machines) – EMAG 2D/3D – Stress analysis (FE based solver) & vibro acoustic

Electric ic Machine Simula latio ions

A true multi-physics problem

Losses / Heat Loads

Electromagnetics Thermal / CFD

CD-adapco Tools ls For Electric ic Machines

SPEED to STAR-CCM+ Workflow (for thermal design)

• 2. Desing check with

static and dynamic analytical analysis

• 3. FE-analysis and fitting
• f the analytical model
• 5. Transfer of the heat loss

distribution from the FE- analysis to STAR-CCM+ via the sbd-file

• 6. Mapping process for rotor and stator

heat losses is carried out separately and automatically with transfer of the values from neighbor grid node in SPEED to STAR-CCM+

• 1. Create SPEED model

based on geometry, parameters, & winding scheme

• 4. Preparation of the geometry

in STAR-CCM+ by reading the xGDF file

• 7. Solving and post processing

in STAR-CCM+

Electric machine design solution – Template based geometry, analytic tool + models for 3D effects, 2D FEA solver. Multi-physics, general purpose simulation solution General geometry, 3D finite volume CFD solvers

Therma mal l Consid ideratio ions

Heat flows through coils fast along the direction of the copper, slow perpendicularly to it. The Material is then anisotropic

– Wire Bundles: copper conducts heat better than insulation, varnish, potting material or air. – Lamination Stack: Steel conducts faster than insulation coating – Both physically modeled by setting 2 values for thermal conductivity: ∥ and

How to determine the direction field?

– Set Direction field from coil geometry – Bulk Coil model can use analytic expression for the direction field. (streamlines of the direction field are shown and look like winding pattern)

∥

• 3. Run thermal calculations

in Motor-CAD to check the model

• 2. FE-analysis and fitting
• f the analytical model
• 5. Transfer of the heat loss

distribution from the FE- analysis to STAR-CCM+ via the sbd-file FE-grid SPEED FV-grid STAR-CCM+

• 1. Creation of the

Motor-CAD model based on geometry parameters and winding scheme or import from SPEED

Data transfer

• 4. Preparation of the geometry

in STAR-CCM+ by running a Java script

• 7. Solving and post processing

in STAR-CCM+

• 6. Mapping process for rotor and stator heat losses

is carried out separately and automatically with transfer of the values from neighbor grid node in SPEED to STAR-CCM+

Therma mal l Modelin ling

SPEED/Motor-CAD/STAR-CCM+

• FE EMAG Loss Calculation

– From SPEED

• STAR-CCM+ cooling analysis

– Conjugate heat transfer using liquid and/or gaseous coolants – Import of thermal loading from EMAG tool

Therma mal l Modelin ling

Links with other software supplier: JMAG, FLUX, Motor-CAD, …

• 2D loss distribution data is

mapped onto STAR-CCM+ grid

• 2D or 3D loss distribution data is

mapped onto STAR-CCM+ grid – From JMAG (JSOL, Japan) – From Flux (Cedrat/Magsoft, France/US) – From Motor-CAD (MDL, UK)

JSOL/CD-adapco Announceme ment

July, 2014

JMAG/STAR-CCM+

Co-sim possibilities

Legacy Methods JMAG > Nastran files > STAR-CCM+ STAR-CCM+ > Nastran > JMAG Automatic Methods JAVA based coupling Injector example First development deliverable Volume to Volume API Electric Machine (3D EMAG > 3D Thermal > 3D EMAG > 3D Thermal > …) Future developments Possible 2D EMAG > 3D Thermal > 2D EMAG > 3D Thermal > …

Low speed: 600 rpm High speed: 8,000 rpm Loss density Copper loss density distribution JMAG Iron loss density distribution JMAG Magnet loss density distribution JMAG

Example le: Loss import from JMAG

The model, losses and load cases

JMAG model

JMAG Examp mple le

Losses vs. speed

Low speed (600 rpm)

– Copper losses are dominating.

Medium speed (4,000 rpm)

– Iron losses are slightly higher than copper losses

High speed (8,000 rpm)

– Iron losses are dominating.

Magnet losses are negligible

Speed rpm Current A Torque Nm Output kW Copper loss W Iron loss W Magnet loss W 600 84.8 22.8 14.3 334.4 17.2 0.20 4000 60.0 18.5 7.7 167.4 268.1 2.14 8000 30.4 9.1 7.6 43.0 345.3 0.74

Low speed Medium speed High speed

Example le 2:

Model Set-up in STAR-CCM+

Simulation goal: Steady state temperatures

Water cooled housing, coolant induced at 40°C, 0.25 m/s Winding region with bulk end windings Venting holes in the rotor at representative shaft radius of JMAG model Moving reference frame model to allow for the rotation of the rotor Runtime – Mesh: 2,7Mio. polyhedral cells – Converges within 200 iterations – Computation time: runs on 5 cores in 36 minutes

#19.IGS: 3D cad model for thermal analysis (iges format)

Low speed: 600 rpm High speed: 8,000 rpm Mapped imported heat loss distribution in STAR-CCM+ Temperature distribution in STAR-CCM+

Example le 2: Loss import from JMAG

Mapped losses and temperature distribution

Example le 2:

Transfer of Temperatures back as .NAS files

STAR-CCM+ solution can be mapped back onto NASTRAN grid Export of solution data only to reduce file size Temperature is written as vertex data

– Unit is specified by user 600 RPM 4000 RPM 8000 RPM

Questio ions? SPEED D & S STAR-CCM+