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The “Seminar on Electrical Rotating Machines” held on 12th and 13th of May – 2015 in

Bangalore. The seminar was organized by ProSIM R&D sponsored by JMAG from Japan and

3DS SIMULIA Bangalore.

In the seminar 50 participants from 25 companies from different verticals like automotive,

irrigation, wind and Academics from across India participated viz. Auto Ignition limited,

Kirloskar brothers limited(KBL),Lucas-TVS, Toshiba Mitsubishi Electric Industrial Systems

Corporation India Pvt. Ltd(TMEIC), Automotive Research Association of India (ARAI),

Bharat Bijlee, SE Electricals(Suzlon group), Bosch, Mahindra-REVA, Versa Drives, EBM

Papst Texmo, Jain Irrigation, Aqua Sub, Steinmetz, Agni, Rajmane Motors, Precise small

motors and academic institution like,PSG, Coimbatore, Gandhi Institute of Technology and

Management (GITAM University) Hyderabad, JNTUK , Kakinada etc.

Serious and major technical issues on Interior Permanent Magnet (IPM), Shaded-pole

motors, Alternators, Induction motor(IM ), Brushless DC motor and control system were

discussed and case studies were demonstrated. Experts from industries discussed the

challenges faced by the management and how to take care the designs issues, manufacturing

issues, localization issues during design stage. Technical papers are presented on

electromagnetic, thermal and noise problems and demonstrated how the software are helping

designers to achieve high efficiency and best performance machines.

Key note:

Dr.S.Shamasundar, Managing Director, ProSIM

The welcome speech started by Dr. Shamasundar by introducing ProSIM and its capabilities

in the field of engineering services and expertise in design, validation and optimization of

electrical machines by using latest simulation technologies. He explained about the usage of

FEA and latest simulation technologies by major electrical machine manufacturers to design

a compact, high performance and high efficiency motors. Also he elaborated on how using

simulation FEM models as “virtual test bench” will help in understanding the temperature,

vibration, stress, noise issues and arrive at fatigue life, durability and reliability issues.

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Pic: Welcome speech - Dr. Shamasundar adressing the gathering.

Technical discussions

1. Why electromagnetic analysis is necessary for rotating machines and effect of

materials by - Mr. Hiroyuki Sano (Team Manager - Electromagnetic Engineering

Dept, JSOL Japan)

Material properties play an important role in getting best performance of rotating machines

and it can be easily predicted from electromagnetic analysis by identifying material

saturation level, stacking lamination of core and losses to achieve high efficiency. 3-D

models and assemblies for better visualisation, aesthetics and lower assembly interference

errors can be easily analysed by using JMAG and also effect of materials on output

performance and Effect of shape and size of the insulating material is also important to have

better design and this reality has been showcased successfully by Hiroyuki Sano.

The influence of material magnetic properties on the motor iron loss can be easily studied

using FEA tool JMAG with various non-oriented electrical steel sheets as stator lamination

material. The motor iron loss has a strong correlation with the high-frequency material iron

loss which shows that the armature magnetomotive force causes strong pulses on the

fundamental electromotive force waveform and that these pulses have a large effect on the

motor iron loss.

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Pic: Mr. Hiroyuki Sano, presenting a paper on why electromagnetic simulation is required

for rotating machines.

2. A REVIEW OF THE CHALLENGES POSED TO ELECTRICAL MACHINES

DESIGNERS AND ROLE OF SOFTWARE TOOLS BY - Mr. Sunil Naik (Head -

Product Design, TMEIC Bangalore)

Science behind designing, manufacturing and testing of electrical machines is well

established & proven there are many impediments faced in day-to-day design, manufacture

& testing like torque pulsations, magnetic asymmetries, insulation failures additional noise,

critical speed cusps, Insulation design changes to withstand fast rising impulse voltages or

due to switching or lightning in VFD motors and many more challenges have been

overcome by intelligent design & manufacturing efforts by using Simulation tools. By

using software analysis tools we can check what are the scenarios and What are the major

problems in design stage which can be overcome by using analysis tools with reduced costs

and time.

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Pic: Mr. Vikram, ProSIM presenting memento to Mr. Sunil Naik, TMEIC.

3. Design validation using simulation by - Ms. Aruna (Team lead - EMAG ProSIM

Bangalore)

Motor performances like torque speed characteristics, power speed curve, efficiency vs

speed curves etc are studied using design tool. She demonstrated how simulation helps the

designer to verify their design by studying magnetic flux distribution which helps to verify

no. of poles by visualisation of flux lines. Also simulation supports to know that the

material considered will get saturated or not. Copper losses and iron losses are determined

from the simulation tool, which helps to improve efficiency by reducing losses. By varying

different parameters, optimized design of motor is achieved by using simulation.

Realistic conditions like(Environmental conditions) temperature, Thermal expansion and

stress dependence, etc can be take into consideration in simulation tools(

JMAG,ABAQUS).

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Pic: Mrs. Aruna, ProSIM presenting a paper on design validation using simulation.

4. Real-time control of motors by - Mr. Takashi Kondo (Engineer - Electromagnetic

Engineering DEPT Japan)

How we can use JMAG Express and JMAG RT to achieve the better performances by doing

parametric optimization of geometry and how we can control the motors by using third

party softwares like MAT Lab and Opal RT etc and how we can plot the efficiency maps ,

Ld & Lq maps were explained.

JMAG-RT generates a high fidelity plant model. Since the model is still numerically based,

it can solve very quickly. And since it is based on Finite Element Model results, it will not

sacrifice accuracy to achieve this calculation speed. The JMAG-RT plant model can be used

in system level simulations to provide a more accurate representation of the electromagnetic

device. The JMAG-RT block can be used in Hardware in the Loop Simulations (HILS)

which connect a physical Electronic Control Unit (ECU) to a virtual motor.

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Pic: Discussion during Mr. Kondo’s presentation on JMAG-RT and control technics.

5. 3D Transient analysis of a claw pole alternator using JMAG - Mr. Vigneshwaran

(Sr.Engineer - LUCAS TVS Chennai)

Demand of high fuel efficiency in vehicles has been growing every year so alternator needs

to be designed with a 3D geometry to account for the claw poles and the analysis needs to

consider eddy currents generated in the surface of the claw poles, which are made from a

metal plate, an electromagnetic field analysis using the finite element method would be the

most useful, as it can simulate detailed geometries and account for eddy currents.

By using JMAG, Designer can create a best design by considering the all major points like

eddy currents, flux distribution and the penetration of the eddy current by giving the proper

skin depth. How we can reduce the time by using axial reverse condition and how we can

validate the design using JMAG.

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Pic: Mr. Vigneshwaran, Lucas-TVS delivering the speech.

6. Design of AC / DC Motors with fundamental issues and application areas –

Mr. C S Ravi Prasad, ProSIM

The design of motors from scratch were discussed and the factors needs to be considered

during the design and also the factors affecting the performance of motors , He was

discussed on the basic attributes a designer needs to have before designing any machine.

Designer should take care of the effect of environmental factors, Which should not affect

the performances of the motor in any of the tropical regions. Problems encountered during

the design stage like Steel and Copper ratio, Improper communication angle, Mechanical

unbalanced due to misalignment, improper insulation, losses calculation (thermal and NVH

issues) were discussed.

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Pic: Mr. Ravi Prasad, ProSIM speaking to the audience on fundamentals of design.

7. Measurement of vibration and noise by - Mr. Krishna (Principle Engineer NV

Dynamics Bangalore) and Dr. Suresh Nagesh (CAE Expert)

Sources & causes of Noise and vibration in electrical machines like Unbalance / Mis-

alignment / Bent Shaft, Run-outs / Looseness Resonance and Critical Speeds Mounting

conditions, levels, grouting, coupling load and Torsional loads, Faulty bearings were

discussed and also participants like Suzlon, Versa drives, EBM Papst and TMEIC were

involved.

About Uneven magnetic forces, Pole pitch error, Weak or broken bars, Dynamic Bow

effects, Electrical input quality etc are the major noise sources and that can be easily

analyze by using FEA tools.

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Pic: Dr.Suresh , explaining a question to the audience.

8. Multi - physics simulations by - Ms. Geetha Avula (3ds Simulia Bangalore)

She has given a basic introduction of Abaqus unified FEA product suite which offers

powerful and complete solutions for both routine and sophisticated engineering problems

covering a vast spectrum of industrial applications. In the automotive industry engineering

work groups are able to consider full vehicle loads, dynamic vibration, multi body systems,

impact/crash, nonlinear static, thermal coupling, and acoustic-structural coupling using a

common model data structure and integrated solver technology.

Abaqus/CFD provides advanced computational fluid dynamics capabilities with extensive

support for pre-processing and post processing provided in Abaqus/CAE. These scalable

parallel CFD simulation capabilities address a broad range of nonlinear coupled fluid-

thermal and fluid-structural problems can be done.

.

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Pic: Mr. Balaji, ProSIM presenting memento to Mrs. Geetha Avula, 3ds Bangalore.

10. Introduction to Fatigue of MOTORS and Computational fluid dynamics(CFD) BY

- Mr.Shridhar & Mr.Saurabh Anand ProSIM Bangalore

Fatigue is a process in which damage is accumulated in a material undergoing fluctuating

(cyclic) loading, finally resulting in failure even if the maximum load is well below the

elastic limit of the material being used.

How to analyse the stress in the shrink fit, stresses developed due to the application of the

load, predict the life of the bearings were discussed and also by using fesafe tool designer

can accurately identify the fatigue hotspots, optimize the design to use less material,

Validate the design and test programs, Improve correlation between test and analysis within

a single user interface and also reduce prototype test times speed up analysis times, thereby

reducing man-time hours.

Saurabh has explained about how motor will fails due heat, unusual Mechanical

Loads,power Supply Anomalies,improper Lubrication, etc When a load varies along a

sinusoidal curve, or is cyclic in nature, it is a harmonic load.

By using Abaqus/CFD we can analyze the temperature distribution by considering all the

points like forced cooled, Self cooled temperature raise and temperature distribution can be

studied. Internal or external flows that are steady-state or transient, span a broad Reynolds

number range, and involve complex geometry may be simulated with Abaqus/CFD. This

includes flow problems induced by spatially varying distributed body forces.

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11. Performance Improvements of an Interior Permanent Magnet motor BY-

Mr.Siddesh.S (Application Engineer - ProSIM Bangalore)

He explained about what are the factors affects the performance characteristics of an

interior permanent magnet motor(IPM) like Influence of air gap length on air gap flux

density, Influence of shaft material on air gap flux density and also Influence of pole arc

co-efficient and magnet thickness on air gap flux density.

He showcased the detailed electromagnetic analysis, iron loss analysis and coupled

thermal analysis to predict the temperature distribution on all parts and also he elaborated

by doing parameterization we can increase the efficiency by reducing the losses and also

thermal issues can be solved in IPM motor.

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Pic: Mr.Siddesh.s ProSIM speaking to the audience on influence of air gap length in interior

permanent magnet motors(IPM)

Open house Discussions

Many questions on Interior Permanent Magnet (IPM), Shaded-pole motors(SPM),

Alternators, alternator, induction motor, Brushless DC motor and control system were

discussed. It was a very interactive session. Capabilities of JMAG were discussed in depth.

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Summary:

The speakers covered the basic procedure to start design, factors affecting the design and

why simulation is required to design rotating electrical machines. Effect of material on

output characteristics of the machines, mechanical issues like stress, fatigue and selection of

bearing, Thermal issues like temperature distribution and noise issues were discussed.

Many other issues like how electrical machine designers can adopt new technologies to

improve the performances of motors, alternators and optimize the design by using software

tools like JMAG, ABAQUS and Fe-safe were shown.

It was expressed that by coupling JMAG and ABAQUS, CFD analysis can be performed.

Also that fatigue, durability and RLA studies can be performed by combining ABAQUS and

Fe-safe.