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 • Automatically links from SPEED to Motor-CAD and Motor- CAD to SPEED • Calibration of the SPEED thermal model using Motor-CAD 2 2
Motor Design Ltd Based in Ellesmere, Shropshire, UK On England/Wales border South of Chester and Liverpool MDL Team: Dave Staton (Software Development & Consultancy) Mircea Popescu (Consultancy) Douglas Hawkins (Software Development & Consultancy) Gyula Vainel (Motor Design Engineer) Lyndon Evans (Software Development) Lilo Bluhm (Office Manager) Many University Links: Sponsor 3 Students at present Bristol University Edinburgh University Sheffield University 3
Motor Design Ltd (MDL) set up in 1998 to develop software for design of electric motors and provide motor design consulting and training distribute SPEED , Motor-CAD , FLUX and PORTUNUS software complete package for electric motor and drive simulation software package also used in our consulting work developed the following software products: Motor-CAD – Analytical Network Software for Thermal Analysis of Electric Machines PORTUNUS Thermal Library - system simulation software for thermal simulation of any device Other software currently under development to make the design process easier for the user (link to SPEED software): Motor-LAB developed with EngD student at Bristol – new software to optimise design for full torque/speed envelope rather than a single torque/speed Motor-FLOW to allow the user to automate SPEED/Motor-CAD calculations without having to write a computer script (draw a flow diagram instead) Eff-MAP model run in Motor-FLOW to calculate and plot efficiency maps 4
Motor Design Software Suite the worlds leading analytical software package for the • SPEED design of electric motors (with integrated FEA) unique analytical software package for the thermal • Motor-CAD 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 • FLUX electromagnetic simulation of electric motors • PORTUNUS 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 • STAR-CCM+ now have STAR-CCM+ for advanced thermal analysis using CFD 5 5
Motor Design Software Suite • Complete software solution for electric motor & drive simulation and design IPM T/S PC-BDC 50.00 45.00 40.00 T[gamma=0] 35.00 T[gamma=10] T[gamma=20] 30.00 Torque [Nm] T[gamma=30] 25.00 T[gamma=40] T[gamma=50] 20.00 T[gamma=60] T[gamma=70] 15.00 T[gamma=80] 10.00 5.00 0.00 0 2500 5000 7500 10000 SPEED [RPM] 6 6
Motor-CAD Software • Analytical network analysis package dedicated to thermal analysis of electric motors and generators input geometry using dedicated editors select cooling type, materials, etc. and calculate steady state or transient temperatures all difficult heat transfer data calculated automatically easy to use by non heat transfer specialists provides a detailed understanding of cooling and facilitates optimisation what-if and sensitivity analysis Near instantaneous calculation speeds 7
Thermal Network Analysis • similar to electrical network – 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 • In Motor-CAD the thermal network is automatically set up based on the motor geometry and cooling type selected 8
Motor-CAD Motor Types • Brushless Permanent Magnet • Induction • 3ph and single phase • Switched Reluctance 9
Motor-CAD Motor Types • PMDC • Outer Rotor BPM • Claw Pole • Synchronous 10
Motor-CAD Cooling Types Motor-CAD includes proven models for an extensive range of cooling types – Natural Convection (TENV) • many housing design types – Forced Convection – (TEFC) • many fin channel design types – Through Ventilation • rotor and stator cooling ducts – Open end-shield cooling – Water Jackets • many design types (axial and circumferential ducts) • stator and rotor water jackets – Submersible cooling – Wet Rotor & Wet Stator cooling – Spray Cooling – Direct conductor cooling • Slot water jacket – Conduction • Internal conduction and the effects of mounting – Radiation • Internal and external 11
Motor-CAD Housing Types • Many housing designs can be modeled and optimized – 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 12
Steady-State/Transient Analysis Motor-CAD can be used to calculate both the steady-state and transient duty cycle thermal performance 13
Accurate results with Motor-CAD • A few of the many excellent comparisons between Motor- CAD and test data: 14
Motor-CAD Users • Some of the many Motor-CAD users: –aerospace, automotive, industrial, renewable, transport and university sectors: ABB Otis Elevators Dupont Alarko Carrier Parker Hannifin Eaton Alstom Ecotecnica Peugeot Esterline Ametek Porsche Ford BAE Systems Precilec GE Energy Bombardier Transportation QinetiQ GE Transportaion Bosch Renault General Dynamics BMW Rolls Royce General Motors Brose SEM Goodrich Aerospace Caterpillar Siemens Grundfos Continental Thales Hewlett Packard Cummins Valeo Johnson Electric Crompton Greaves Vestas Wind Systems Kollmorgen Daewoo Visteon Liebherr Aerospace Daimler Volvo Lockhead Martin Dana VW Magna Danaher Motion WEG Magneti Marelli Delphi Corporation Whirlpool Moog 15
SPEED & Motor-CAD Together • SPEED is predominantly used for electromagnetic performance prediction – very simple thermal network models built into software but require calibration • Motor-CAD has sophisticated thermal models that require the user to have NO knowledge of heat transfer • To predict the performance accurately both packages can be used together – losses are critically dependent on temperature – temperatures are critically dependent on loss • Automated links ease the transfer of geometry, loss and temperature data between packages 16
SPEED & Motor-CAD Together • Both SPEED and Motor-CAD are analytical analysis packages providing instantaneous calculation speeds • Most Importantly - the user just needs to input the geometry and selects a few winding/drive/material options and then all the difficult magnetic and heat transfer parameters are calculated automatically – User need not be a magnetic or thermal expert – Also ideal for training • Both SPEED and Motor-CAD are excellent for carrying out “What If” calculations – 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. 17
Motor-CAD & SPEED Complement Each Other • Motor-CAD fits ideally Design Aims alongside SPEED to give instantaneous answers to Possible Solutions design questions – electromagnetic and thermal Specialist Motor Design Packages • Both have a similar user [Electomagnetic & Thermal] e.g. Electromagnetic - Speed interface and work with Thermal - Motor-CAD parameters such as Tw (tooth width), SD (slot depth), etc. Numerical Analysis [Electomagnetic & Thermal] • Automated data transfer e.g. Electromagnetic - Flux-2d & Flux-3d Thermal - CFD between packages – Geometry Prototypes & Test – Losses – Temperatures 18
SPEED Thermal Models • SPEED has a range of thermal models but the user must set them up in order to obtain reliable results – This process assumes the user has some test data or can be done automatically using Motor-CAD 19
SPEED Thermal Models • If SPEED thermal models are not set up the user can predict false temperatures and so inaccurate performance data (losses, efficiency, etc.) • SPEED steady state simple models shown below: 20
SPEED Thermal Models • SPEED transient model shown below • SPEED thermal model not recommended for general use if not calibrated by Motor-CAD or test 21
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