STAR-CCM+ CM+ and SPE PEED ED for electric ctric machines ines - - PowerPoint PPT Presentation

STAR-CCM+ CM+ and SPE PEED ED for electric ctric machines ines cooling ing analysis ysis

Stefan an Holst st

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

• ns lead

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

Ohmi mic c heat ating ing in all condu nducti cting ng parts

– Windings, laminated rotor and stator core and magnets – Winding/copper losses are usually the largest contributor

Hystere eresis is effects ects most stly ly in steel eel parts s Simulat ation ion thes ese effect ects direct ectly ly requi uire res coup upled led transi sien ent t EM EMAG run un

– Very costly for a design calculation

Not

• te:

: Loss

• sses

es occu cur r locall lly

Loss ss mechan anisms isms and dist strib ibut ution ion

Steinm einmetz tz Loss s calculation lation

Al Alternativ rnative e to coup upled led simula ulati tion

• n

– Hysteresis and eddy currents are mostly driven by changes in the magnetic field – Get magnetic field for various rotor positions and attribute losses to size of field changes – Strong variation in the teeth

Magne nets s shield eld the e rot

• tor
• r core

re

Work rkflo flow w diagram gram

Initial 2D Machine Layout

• Perform EMAG layout
• Perform thermal circuit

simulation of duty cycles 10-16 nodes

Geometry Import

• Meshing automatically specified
• Physical setup
• Either CHT
• Or EMAG
• Or even coupled

Heat Loads from SPEED

• Import via STAR-CCM+ file

format *.sbd

• Surface data needs to be

mapped to volume

Geome metr try impor port

xGDF & & xDEF EF files es contain tain the comple lete e EMAG G set etup in XML

• Curren

ently ly only Geome

• metr

try impo mport

• Future

e ver ersions sions includ lude e physics ics and d mode dels ls for end-windin indings, s, skew

Cooling ling mechanism anism

Ai Air cooled

• led

– Exterior and interior

Spray y cooli

• ling

ng of the e end d windin ndings gs Water er cool

• ling

ing around nd the e stator

• r

– More on that now

Heat t conduc nducti tion,

• n, convecti

ection

• n and radiation

diation in the e interior erior air 1l/min min water er pum umped ed throu

• ugh

gh How How to keep ep the e rot

• tor
• r cool
• l?

Resu sults lts for a c coolin ling g jacket t around und the stat ator

• r

Four CAD features later we’ve got holes in the rotor Remesh mesh and fur urth ther er itera rati ting ng gives

Introdu

• duce

ce holes es into the e rotor

• r

Loss sses s are given en in 2D but ut the e therm rmal l simula ulati tion

• n is in 3D

Data Mapper r fun uncti ction

• nality

ality exten ension ion to fa facilit itate e precis ise e mapping ng even en for skewed ed machi chine nes s will come me with th 7.04

– Improved mapping quality compared to current nearest neighbour interpolation

Three ree mappings ings are define ined d here re:

– Rotor – Stator – Windings

SPEE EED only ly provides vides total

• tal losses

ses in magne nets

Data a Mapper er

Ex Examples les so fa far have e been en hand d made de 3D CAD AD cons nstr tructi tions

• ns

Suppor port t for end windin dings gs

Magne netos

• sta

tatic tic run uns s for differen erent t rot

• tor
• r positi

tion

• ns

Glimpse pse on the EMAG G solver er

Low w freq equenc ency y electr ctro-magne magnetic tic solver er

– Frequency/domain size determines applicability

• An e-machines frequency range might not be allowed in areas like mine

detection with far larger length scales

Coup upled led transient nsient and d magne netost

• stat

atic mode

• de

– Magnetostatic can be coupled with motion to cater for loss calculations

Non

• n-line

inear r mater erial ial sup uppor

• rt

– SPEED model import brings in BH-curves – Tabular data or functional description – Isotropic electric conductivity and permeability

Glimpse pse on the EMAG G solver er

Circuit uit

– Transient 3D requires feedback from the circuit

• Extend circuit capability in BSM for general use

– Flux linkage report for electromagnetic circuit elements

Field eld simula ulati tion

• n

– Hysteresis modeling

• Residual magnetism

– Force/Torque calculation – Anisotropy

• Electric conductivity and

permeability

• Infrastructure

EMAG G solver er outlook look

Thank k you!

Thank nk you