The use of Simulation mulation in Elect ectric ic Machin ine e Design ign Stef efan n Holst, lst, CD CD-adapco dapco
Motiv ivati ation on How w often n can a machine hine be started ed with thin n an hour ur In Hybrids rids, , what t effect ect has the e adjacen cent t combustion mbustion drive e train Space ce restr tricti ction ons s opposin osing g power r requi uire reme ments nts in gene neral al In batteries eries, , overhe heati ting ng leads ds to fa faster aging A jo A joint nt si simulation ulation approach ach allows ws to si simulat ulate e the e coup uple led electr ctric ic and thermal ermal problem blem early y on in the e design sign process cess
CD CD- adapco’s Purpose CD CD- adapco’s purpose is to inspire innovation while reducing customer costs ts through ugh the e app pplicati tion on of eng nginee eering ng simu mulati tion on 3
CD-ada CD adapc pco: o: Engi gineerin neering g Su Succes ess Our purpose is to ensure the customer’s success through the use of engineering simulation • Enable & inspire innovation • Reduce engineering time & costs We provide successful engineering simulation solutions • Software products like STAR-CCM+ that are accurate, efficient, and easy to use • Flow, Thermal and Stress simulation in a single tool. • Local dedicated support • Engineering services: technology transfer, burst engineering resources, custom software tools We are a growing and successful engineering simulation company • 20% growth in FY2011 global software sales • $138m End User Spend in FY2011 • >700 employees in ~25 offices • 40% of employees involved in Research and Development activities • >8000 users worldwide Our independence breeds engineering success • Largest independent CAE/CFD provider 4 • Heavily invest in employees • Continuously invest in development of new technology
Overvie view 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 ons 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 om 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
Early rly to mid stages ages of machine ine design ign SPEE EED is the e leading ding design esign softw tware are for or elect lectri ric c machi chine nes – Detailed analytical analysis with finite-element links or finite-embedded solver for • motors, generators and alternators • including inverters and other electronic controls Special cialize ized d tool ols per mot otor or type e imp mprove e design ign efficie iciency ncy – PC-BDC for brushless permanent magnet and wound-field AC synchronous – PC-IMD for induction machines – PC-SRD for switched reluctance – PC-DCM for direct current (PM) – PC-WFC for wound field and PM commut.
SP SPEED ED – The e desi sign gn process cess 1 2 3 7 4 6 5 8
Equiv ivalent alent circuit uit meth ethods ods Inst stantane ntaneous ous results ts with th todays ys comput puters As Assumpti tion ons s on flux ux path and mathe hematical tical mode dels s give e estima imates es on circui uit t parame meter r – Inter phase dependence is difficult to incorporate (SRM) – Modeling assumptions have certain validity range only How How to keep ep computa putati tiona onal l sp speed eed but ut extend end applicabi ability lity – Use 2D/3D FEA to calibrate, but limit to as to few key simulation conditions
SP SPEED ED in use: GoFE FER Go Go to Finite-Elements and Return Two FE runs only … or use the embedded FE -solver directly (PC-BDC)
Data a transf ansfer er to STAR-CC CCM+ The e B-fiel ield d variation ion allows ws iron n loss ss estimati stimation on – GoFER of 72 rotor positions /elec. revolution – Modified Steinmetz method in SPEED applies also to non sinusoidal currents – Element Table tool to view and export cell-wise values
Therm rmal l modell ellin ing g in STAR AR-CCM+ CCM+ Simulat ation ion goal: l: steady ady state e temperatu peratures res A w A water er cooled oled casing ng and end d windin nding g regions ions are added ded to the e SPEE EED model odel imp mpor ort – Coolant is induced at 50 ° C, at a volume flow rate of 1 l/s Iden entify tify inter erface ces where ere thermal ermal resis istan tance ces s model odel neglec glected d fine e detail etails – slot liner, stator to housing contact imperfections, magnet to rotor contact Rot otat ation ion is modeled odeled with h a movi ving ng referer erernce ce approa oach ch – Source to the momentum equation in a domain enclosing the rotor and shaft parts Example taken from the paper “STAR -CCM+ and SPEED for electric machine cooling analysis”, CWIEME 2012, Berlin
Therm rmal l modell ellin ing in n STAR AR-CCM+ CCM+ Resolving solving each ch wire e is too o cost stly – Model winding as bulk region – Gaps between wires and wire insulation are accounted for using anisotropic material properties – Local wire orientation is interpolated from easily selectable edge orientation – Off directional thermal conductivities is tuned to resemble spread between mean and max winding temperatures Ai Air and cool olant ant flo low w is solved ed us using g standar ndard d tur urbulence lence mode del set etti ting ngs s in STAR AR-CC CCM+ M+
Resu sults lts 1000 rpm Using ng the e STAR AR-CC CCM+ M+ coup upled led so solver er in the e flow w converge ges s within hin 120 itera rati tions ons 6000 rpm The e tempera perature ture distribution ribution clearl rly y indica icates that t the e windin ndings gs closer er to the e cool olant ant out utlet t are un under der higher her therm rmal l stress ess
SP SPEED ED and nd STAR-CCM CM+ – the combin mbined ed workfl flow for Elec ectr tric ical al Mach chin ines es Reading the SPEED geometry and the loss distribution PC-FEA: Loss table Running the final calculation advanced thermal calculation . Initial design with SPEED Temperatures impact life time, reliability, cost & size
Applications Hydraulics E-mo motor or simulations mulations IC engines Electro-magnetic systems Battery control STAR-CCM+ CM+ v8.02 coup uples les with h 1D co D codes – AMESIM – Wave – OLGA – And via scripting also to Matlab/Simulink Applicati ications ons – Full vehicle simulation • Drive cycle simulations • Control of the battery – Prevent excessive loading on high temperature 15 15
Protocol col Design ign Start Specify input: simulation • field functions Specify Update circuit • Open port • time step size reports time step …… Macro Store list of Run Step connects to reports • Send reports Simulink port
Matlab lab/Si /Simulin ulink k
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