Motor-CAD Training Session

Motor-CAD Links to SPEED

Mircea Popescu & Dave Staton

Motor Design Ltd

March 2012

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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

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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

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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

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Motor Design Software Suite • SPEED

• Motor-CAD

• FLUX

• PORTUNUS

• STAR-CCM+

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

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

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Motor Design Software Suite • Complete software solution for electric motor & drive simulation and design

IPM T/S PC-BDC

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

45.00

50.00

0 2500 5000 7500 10000

SPEED [RPM]

To

rqu

e [

Nm

]

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]

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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

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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

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Motor-CAD Motor Types

• Brushless Permanent Magnet

• Induction • 3ph and single phase

• Switched Reluctance

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Motor-CAD Motor Types

• Outer Rotor BPM

• Claw Pole

• Synchronous

• PMDC

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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

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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

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Steady-State/Transient Analysis Motor-CAD can be used to calculate both the steady-state and transient duty cycle thermal performance

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Accurate results with Motor-CAD • A few of the many excellent comparisons between Motor-

CAD and test data:

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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

Otis Elevators

Parker Hannifin

Peugeot

Porsche

Precilec

QinetiQ

Renault

Rolls Royce

SEM

Siemens

Thales

Valeo

Vestas Wind Systems

Visteon

Volvo

VW

WEG

Whirlpool

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

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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

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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.

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Motor-CAD & SPEED Complement Each Other

Design Aims

Possible Solutions

Specialist Motor Design Packages [Electomagnetic & Thermal] e.g. Electromagnetic - Speed

Thermal - Motor-CAD

Prototypes & Test

Numerical Analysis [Electomagnetic & Thermal]

e.g. Electromagnetic - Flux-2d & Flux-3d Thermal - CFD

• 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

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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

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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:

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SPEED Thermal Models • SPEED transient model shown below

• SPEED thermal model not recommended for

general use if not calibrated by Motor-CAD or test

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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

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Motor-CAD Links to 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

• Run option from Motor-CAD using [Sp] button

• Automatically runs SPEED

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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.

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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

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

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• Export the data to Motor-CAD

SPEED / Motor-CAD Link Example

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• 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


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• We can set the thermal resistance between winding-ambient in SPEED to be 2C/W – Motor-CAD and SPEED now give similar results


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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, stator-housing, rotor-stator, etc).

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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

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• 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

GoTar Example (PC-BDC)

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• Imported winding details

– Imported wire size and turns correctly

– Colours represent amounts of copper (yellow) and insulation (green)


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• Imported losses GoTar Example (PC-BDC)

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• Predicted temperatures GoTar Example (PC-BDC)

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• 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.


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

TempCalc = Fixed

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• Check Select/Deselect all value and press [Iterate] • Good prediction of winding temperature

TempCalc = DegCW

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

TempCalc = ThRcct

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• 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)

TempCalc = Hot10

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• Many parameters are calibrated TempCalc = Hot10

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• 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

TempCalc = Hot10

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• We can also compare the calibrated Hot10 and Motor-CAD transient graphs – Should plot magnet and winding average temperature

TempCalc = Hot10

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• 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):

TempCalc = Hot10

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• 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

SPEED/Motor-CAD Links

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• 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 steady-

state 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

SPEED Thermal Model Recommendations

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• 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

SPEED Thermal Model Recommendations

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Motor-CAD Training Session