Multi-Physics Tool for Electrical Machine Sizing

Moreno, Yerai; Almandoz, Gaizka; Egea, Aritz; Madina, Patxi; Escalada, Ana Julia

doi:10.3390/en13071651

Cited by 6 publications

(3 citation statements)

References 17 publications

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“…Moreover, the model setup as well as its resolution are usually very time consuming. Because of these drawbacks, engineers working in manufacturing companies often limit numerical thermal analyses only to the final design stage, occasionally using multiphysics models for a comprehensive performance assessment of the electric machines [16,17]. Sometimes, electromagnetic and thermal numerical co-simulations are conducted to assess faulty conditions [18].…”

Section: Lumped-parameters Thermal Models For Pm Synchronous Machinesmentioning

confidence: 99%

Lumped-Parameters Thermal Network of PM Synchronous Machines for Automotive Brake-by-Wire Systems

Graffeo

Vaschetto

Miotto³

et al. 2021

Energies

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Thermal analysis represents a key factor in electrical machine design due to the impact of temperature increase on insulation lifetime. In this context, there has been a wide investigation on thermal modeling, particularly for machines used in harsh working conditions. In this perspective, brake-by-wire (BBW) systems represent one of the most challenging applications for electrical machines used for automotive smart actuators. Indeed, electro-actuated braking systems are required to repeatedly operate the electric machine in high overload conditions in order to limit the actuator response time, as well as to enhance gravimetric and volumetric specific performance indexes. Moreover, BBW systems often impose unconventional supply conditions to the electric machine, consisting of dc currents in three-phase windings to keep the rotor fixed during the braking intervals. However, a dc supply leads to uneven temperature distributions in the machine, and simplified thermal models may not accurately represent the temperature variations for the different machine parts. Considering such unconventional supply conditions, this paper initially investigates the applicability of a conventional lumped-parameters thermal network (LPTN) based on symmetry assumptions for the heat paths and suitable for surface-mounted PM synchronous machines used in BBW systems. An extensive test campaign consisting of pulses and load cycle tests representative of the real machine operations was conducted on a prototype equipped with several temperature sensors. The comparison between measurements and predicted average temperatures, together with insights on the unbalanced heat distribution under the dc supply obtained by means of finite element analyses (FEA), paved the way for the proposal of a phase-split LPTN with optimized parameters. The paper also includes a critical analysis of the optimized parameters, proposing a simplified, phase-split lumped-parameters thermal model suitable to predict the temperature variations in the different machine parts for PM synchronous electric machines used in BBW systems.

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Section: Lumped-parameters Thermal Models For Pm Synchronous Machinesmentioning

confidence: 99%

Lumped-Parameters Thermal Network of PM Synchronous Machines for Automotive Brake-by-Wire Systems

Graffeo

Vaschetto

Miotto³

et al. 2021

Energies

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“…It uses a combination of advanced analytical equations and calculations based on 2D FEM. The temperature can be determined in steady and transient conditions; the program uses advanced models in the form of thermal networks [37][38][39][40][41][42].…”

Section: Computational Modelsmentioning

confidence: 99%

Selected Aspects of Decreasing Weight of Motor Dedicated to Wheel Hub Assembly by Increasing Number of Magnetic Poles

Dukalski

Krok

2021

Energies

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Decreasing the mass of a wheel hub motor by improving the design of a motor’s electromagnetic circuit is discussed in this paper. The authors propose to increase the number of magnetic pole pairs. They present possibilities of mass reduction obtained by these means. They also analyze the impact of design changes on losses and temperature distribution in motor elements. Lab tests of a constructed prototype, as well as elaborated conjugate thermal-electromagnetic models of the prototype motor and modified motor (i.e., motor with increased number of magnetic poles) were used in the investigation. Simulation models were verified by tests on the prototype. Results of calculations for two motors, differing by the number of pair poles, were compared over a wide operational range specific to the motor application in the electric traction. A detailed analysis of the operational range for these motors was also made.

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“…Ref. [13] proposes a very fast sizing method that only uses magnetic flux maps and thermal maps that have been previously calculated with FEA and analytical models. The execution time is less than 1 min and the accuracy of results between calculated performance and experimental measurements is about 5%.…”

Section: Introductionmentioning

confidence: 99%

Comparison between Space Mapping and Direct FEA Optimizations for the Design of Halbach Array PM Motor

et al. 2022

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Effective methods for the design of high-performance electrical machines must use optimization techniques and precise and fast physical models. Convergence, precision and speed of execution are important issues, in addition to the ability to explore the entire domain of solutions. The finite element method (FEM) presents a high accuracy in the results but with high computational costs. Analytical models, on the other hand, solve the problem quickly but compromise the accuracy of the results. This work shows a comparison between an optimization made with an analytical electromagnetic model and a direct optimization with finite element field calculation for the optimal design of a Halbach array permanent magnet synchronous motor (PMSM). In the case of the analytical model, it is necessary to use an iterative method of correcting the model to obtain a valid solution. This method is known as Space Mapping (SM) and the analytical model can be improved with a reduced number of iterations with the FEM. The results show a rapid convergence towards an optimal solution for the SM, with more than 78% reduction in computational cost compared to a Direct FEM optimization. Both solutions have only a difference of 3% on the power density, which indicates that FEM does not improve the results obtained by SM. This represents a great advantage that allows for the consideration of a large amount of designs to analyze the domain of solutions in more detail. This study also shows that SM is a powerful method to optimize the power density or torque density of electrical machines.

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Multi-Physics Tool for Electrical Machine Sizing

Cited by 6 publications

References 17 publications

Lumped-Parameters Thermal Network of PM Synchronous Machines for Automotive Brake-by-Wire Systems

Lumped-Parameters Thermal Network of PM Synchronous Machines for Automotive Brake-by-Wire Systems

Selected Aspects of Decreasing Weight of Motor Dedicated to Wheel Hub Assembly by Increasing Number of Magnetic Poles

Comparison between Space Mapping and Direct FEA Optimizations for the Design of Halbach Array PM Motor

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