Software Solutio ions for the Desig ign and Simula latio ion of Electric ic Machines Dr. Markus us Anders, CD-adapco
Agenda 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
About SPEED SPEED is the leading initial design software for electric machines • 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. • Detailed analytical analysis with finite-element links or finite-embedded solver for • motors, generators and alternators • including inverters and GoFER using PC-FEA other electronic controls. • The analytic approach provides nearly instantaneously results (in seconds/minutes). • The embedded FE solver (using PC-FEA) • is a unique capability, • enables our customers to do things SPEED could not otherwise do and • improves the accuracy of SPEED by a substantial margin.
About SPEED • 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) • Over 1000 corporate accounts worldwide • Can link to other FE programs, such as • JMAG • Flux • Opera • …
SPEED D & J JMAG • SPEED models can be easily imported into JMAG by using the GoFER Run Option “Other FEA links …”. • 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
SPEED D & S STAR-CCM+ SPEED’s Bgap GoFER with STAR-CCM+ • 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 & H HEEDS Multi-disciplinary Design Optimization The main features: – Multi-disciplinary, multi-objective parametric design optimization using SHERPA Automated • Multiple search methods by scripting simultaneously, • A combination of global and local search methods, • No tunable parameters; all SPEED parameters are automatically adjusted in an adaptive manner, • Adaptive Parallel Plot showing design trends among designs evaluated during an optimization. – 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
SPEED D & H HEEDS – Very simple optimization example for minimum cogging torque and magnet volume Baseline Design 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 Appr. 2000 calc., 3 hours
SPEED D & H HEEDS – Desig ign Exploratio ion Using the US06 Drive Cycle Motor Design Parameters Geometry Motor Efficiency Results SHERPA Note: Only FEASIBLE Design Concepts Feasible Infeasible are Displayed
STAR-CCM+: General l 3-D Multi-physics & Multi-purpose software STAR-CCM+ is a powerful, all-in-one tool that combines: – Ease of use, – All-in-one software package, – Automatic meshing, CAD STAR-CCM+ Report – 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 Multiphysics & Multipurpose software Integrated engineering solution for CAE Integration solving multidisciplinary problems Multidisciplinary Analyses Surface Preparation Geometry Meshing 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 Electromagnetics Thermal / CFD Losses / Heat Loads
CD-adapco Tools ls For Electric ic Machines SPEED to STAR-CCM+ Workflow (for thermal design) Electric machine design solution – Template based geometry, analytic tool + models for 3D effects, 2D FEA solver. 3. FE-analysis and fitting 1. Create SPEED model of the analytical model based on geometry, parameters, & 4. Preparation of the geometry winding scheme in STAR-CCM+ by reading 2. Desing check with the xGDF file static and dynamic analytical analysis 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 5. Transfer of the heat loss values from neighbor grid node in distribution from the FE- SPEED to STAR-CCM+ analysis to STAR-CCM+ via the sbd-file 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)
Therma mal l Modelin ling SPEED/Motor-CAD/STAR-CCM+ 3. Run thermal calculations in Motor-CAD to check 1. Creation of the the model Motor-CAD model 4. Preparation of the geometry based on geometry in STAR-CCM+ by running a parameters and Java script winding scheme or import from SPEED 2. FE-analysis and fitting of the analytical model FE-grid SPEED FV-grid STAR-CCM+ Data transfer 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+ 5. Transfer of the heat loss distribution from the FE- analysis to STAR-CCM+ via the sbd-file
Therma mal l Modelin ling Links with other software supplier: JMAG, FLUX, Motor-CAD, … FE EMAG Loss Calculation STAR-CCM+ cooling analysis • • – From SPEED – Conjugate heat transfer using liquid and/or gaseous coolants – From JMAG (JSOL, Japan) – Import of thermal loading from EMAG – From Flux (Cedrat/Magsoft, France/US) tool – From Motor-CAD (MDL, UK) • 2D loss distribution data is • 2D or 3D loss distribution data is mapped onto STAR-CCM+ grid mapped onto STAR-CCM+ grid
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 Volume to Volume API deliverable Electric Machine (3D EMAG > 3D Thermal > 3D EMAG > 3D Thermal > …) Future developments Possible 2D EMAG > 3D Thermal > 2D EMAG > 3D Thermal > …
Example le: Loss import from JMAG The model, losses and load cases Low speed: High speed: Loss JMAG model 600 rpm 8,000 rpm density Copper loss density distribution JMAG Iron loss density distribution JMAG Magnet loss density distribution JMAG
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 Low speed Speed Current Torque Output Copper loss Iron loss Magnet loss rpm A Nm kW W W W Medium speed 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 High speed 8000 30.4 9.1 7.6 43.0 345.3 0.74
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 #19.IGS: 3D cad model for thermal analysis shaft radius of JMAG model (iges format) 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
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