Motor-CAD Links to SPEED

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 SPEED Motor-CAD the worlds leading analytical software package for the design of electric motors (with integrated FEA) unique analytical software package for the thermal analysis of electric motors SPEED & Motor-CAD s analytical based algorithms give instantaneous calculation speeds and allow 'what-if' analysis in real time FLUX PORTUNUS STAR-CCM+ finite element software well adapted for accurate electromagnetic simulation of electric motors 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 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 Torque [Nm] 35.00 30.00 25.00 20.00 15.00 T[gamma=0] T[gamma=10] T[gamma=20] T[gamma=30] T[gamma=40] T[gamma=50] T[gamma=60] T[gamma=70] 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 Alarko Carrier Alstom Ecotecnica Ametek BAE Systems Bombardier Transportation Bosch BMW Brose Caterpillar Continental Cummins Crompton Greaves Daewoo Daimler Dana Danaher Motion Delphi Corporation Dupont Eaton Esterline Ford GE Energy GE Transportaion General Dynamics General Motors Goodrich Aerospace Grundfos Hewlett Packard Johnson Electric Kollmorgen Liebherr Aerospace Lockhead Martin Magna Magneti Marelli Moog Otis Elevators Parker Hannifin Peugeot Porsche Precilec QinetiQ Renault Rolls Royce SEM Siemens Thales Valeo Vestas Wind Systems Visteon Volvo VW WEG Whirlpool 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 Design Aims Possible Solutions Specialist Motor De sign Packages [Electomagnetic & Thermal] e.g. Electromagnetic - Speed Thermal - Motor-CAD Numerical Analysis [Electomagnetic & Thermal] e.g. Electromagnetic - Flux-2d & Flux-3d Thermal - CFD Prototypes & Test Motor-CAD fits ideally alongside SPEED to give instantaneous answers to design questions electromagnetic and thermal Both have a similar user interface and work with parameters such as Tw (tooth width), SD (slot depth), etc. Automated data transfer between packages Geometry 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

SPEED/Motor-CAD Link History The original SPEED/Motor-CAD Links were initiated by a call from Motor-CAD to SPEED to import geometry and losses and pass back temperatures first released Motor-CAD v1.6 (October 2002) After this proved successful we developed direct links from SPEED to Motor-CAD Termed GoTAR Go Thermal Analysis and Return ActiveX call to Motor-CAD with most of linkage code implemented in Motor-CAD Facilitates automated calibration of SPEED thermal models User has full control of this calibration process First released in 2007 22

Motor-CAD Links to SPEED Run option from Motor-CAD using [Sp] button Automatically runs SPEED import/export geometry (with choices of what data to transfer) import losses export temperatures [Single Shot] or [Iterate to Converged Solution] loss function of temperature and temperature function of loss 23

SPEED links to Motor-CAD a design can be exported from SPEED to Motor-CAD geometry, winding and losses intelligent geometry scaling means that dimensional details not available in SPEED are given reasonable values housing, endcaps, bearings, etc. 24

SPEED/Motor-CAD Data Links Typical Procedure: import geometry, winding and losses from SPEED with temperatures of winding and magnets at expected values set geometric data for non electromagnetic components such as the housing and bearings set the cooling type and choose materials default materials can often be used initially with fine selection later calculate the temperatures and compare with expectations [Iterate to Converged Solution] to make both models use the same loss and temperature data can change both electromagnetic (SPEED) and thermal (Motor-CAD) designs and try to optimise total solution 25

SPEED / Motor-CAD Link Example Create a new design in SPEED PC-BDC 26

SPEED / Motor-CAD Link Example Export the data to Motor-CAD 27

SPEED / Motor-CAD Link Example In this example SPEED uses a thermal resistance between winding-ambient model to predict the winding temperature but has no value set so Motor-CAD and SPEED have very different results Motor-CAD predicts the thermal resistance between winding and ambient to be 2C/W 28

SPEED / Motor-CAD Link Example We can set the thermal resistance between windingambient in SPEED to be 2C/W Motor-CAD and SPEED now give similar results 29

GoTAR Example (PC-BDC) For a simple example of the GoTAR calibration of the different thermal models in PC-BDC we will use the Alt-1 standard machine (Nd-Fe-B and Xfe = 2) 1. transfer data to Motor-CAD and set temperatures in PC- BDC using Fixed temperature model 2. calibrate the winding-ambient thermal resistance [C/W] 3. calibrate the housing convection/radiation heat transfer coefficient [W/m2/C] and the internal thermal resistances winding-stator and stator-housing 4. calibrate the Hot10 thermal lumped circuit (10 nodes with convection/radiation heat transfer paths on the outside of the machine and internal resistances for winding-stator, winding-end winding, end winding-endcap, statorhousing, rotor-stator, etc). 30

GoTar Example (PC-BDC) Calculate rated performance in PC-BDC with [Dynamic Design] and then export geometry, winding and losses creates a.mot file with same name as.bd4 file in the same folder 31

GoTar Example (PC-BDC) Geometry in Motor-CAD Can fine tune certain dimensional parameters that have no direct equivalent in PC-BDC, housing type, bearings etc. intelligent geometry scaling makes sure all parts fit the size of machine under consideration 32

GoTar Example (PC-BDC) Imported winding details Imported wire size and turns correctly Colours represent amounts of copper (yellow) and insulation (green) 33

GoTar Example (PC-BDC) Imported losses 34

GoTar Example (PC-BDC) Predicted temperatures 35

GoTar Example (PC-BDC) Can study the steady state schematic to see where restrictions to cooling exist and what can be done to make the machine cooler Materials, mounting, improved impregnation, interface gaps, etc. 36

TempCalc = Fixed Check Select/Deselect all value and press [Iterate] Motor-CAD and PC-BDC values of Tw and Tm and losses match 37

TempCalc = DegCW Check Select/Deselect all value and press [Iterate] Good prediction of winding temperature 38

TempCalc = ThRcct Check Select/Deselect all value and press [Iterate] Good match between conductor, stator, housing and magnet temperatures 39

TempCalc = Hot10 PC-BDC carries out a transient solution to find the steady-state temperatures so need to check that steady state reached (200min) Need to set starting temperatures to 20C rather than 25C (ambient) 40

TempCalc = Hot10 Many parameters are calibrated 41

TempCalc = Hot10 Max Heat Bal can be used to see if steady-state is reached in PC-BDC Warning given if PC-BDC not reached steady state 42

TempCalc = Hot10 We can also compare the calibrated Hot10 and Motor-CAD transient graphs Should plot magnet and winding average temperature 43

TempCalc = Hot10 The user can change to a duty cycle in PC-BDC and have accurate predictions of temperatures (3 times current with 50% duty cycle, 10 min): 44

SPEED/Motor-CAD Links Max Heat Bal can be used to see if steady-state is reached in PC-BDC Warning given if PC-BDC not reached steady state 45 45

SPEED Thermal Model Recommendations Most used thermal model in SPEED is the Fixed temperature model Easy to set these temperatures from Motor-CAD (iterative model losses/temperatures available) DegCW & ThRcct models have some limited use if they are calibrated by Motor-CAD Can then change load in SPEED and calculate losses with more accuracy than Fixed temperature model Assumes all thermal quantities in the SPEED model are not functions of rotational speed & temperature Need to re-calibrate if change design Hot10 model in PC-BDC of very limited use as always calculates a transient and so must ensure that time period is long enough if steadystate results required only able to set up limited duty cycle waveforms with Hot10 Must calibrate the Hot10 model each time a change is made to the design otherwise invalid temperature and so overall performance predictions often result Many parameters to calibrate Assumes all thermal quantities in the Hot10 model are not functions of rotational speed & temperature Hot10 model can be unstable 46 46

SPEED Thermal Model Recommendations Best to use Motor-CAD for thermal and SPEED for electromagnetics Motor-CAD has models to scale losses with speed, temperature and load so accurate thermal duty cycle analysis can be performed in Motor-CAD with the losses just input at one fixed speed and load and at set winding and magnet temperatures Only need to predict losses in SPEED at one load point and transfer these to Motor-CAD 47 47