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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 thermalsimulation of any device
Other software currently under development to make the designprocess 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 calculationswithout 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 timefinite 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]
T o r q u e [ N m ]
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 datacalculated automatically
easy to use by non heat transferspecialists
provides a detailed understanding
of cooling and facilitatesoptimisation
what-if and sensitivity analysis
Near instantaneous calculationspeeds
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Thermal Network Analysis• similar to electrical network
– thermal resistances rather thanelectrical resistances
– power sources rather thancurrent sources (losses)
– thermal capacitances rather
than electrical capacitors – nodal temperatures rather than
voltages
– power flow through resistancesrather than current
• In Motor-CAD the thermalnetwork is automatically setup based on the motorgeometry and cooling typeselected
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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 TypesMotor-CAD includes proven models for anextensive 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
S S /
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Steady-State/Transient AnalysisMotor-CAD can be usedto calculate both the
steady-state andtransient duty cyclethermal 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 geometryand selects a few winding/drive/material options and thenall the difficult magnetic and heat transfer parameters arecalculated 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 “ToothWidth”, “Airgap”, “Liner Thickness”, “Turns Per Coil”, “LinerThermal Conductivity”, etc.
– direct access to physical output parameters such as “ShaftTorque”, “Copper Loss”, “Winding Average Temperature”,“Winding Hotspot Temperature”, “Magnet Temperature”, etc.
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Motor-CAD & SPEED Complement
Each OtherDesign Aims
Possible Solutions
Specialist Motor De sign Packages[Electomagnetic & Thermal]e.g. Electromagnetic - Speed
Thermal - Motor-CAD
Prototypes & Test
Numerical Analysis[Electomagnetic & Thermal]
e.g. Electromagnetic - Flux-2d & Flux-3dThermal - CFD
• Motor-CAD fits ideallyalongside SPEED to giveinstantaneous answers todesign questions – electromagnetic and thermal
• Both have a similar userinterface and work withparameters such as Tw(tooth width), SD (slotdepth), etc.
• Automated data transferbetween 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 inaccurateperformance 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 lossesand pass back temperatures
– first released Motor-CAD v1.6 (October 2002)
•
After this proved successful we developed direct links fromSPEED to Motor-CAD
– Termed GoTAR – Go Thermal Analysis and Return
– ActiveX call to Motor-CAD with most of linkage codeimplemented 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 fromMotor-CAD using [Sp]
button
• Automatically runsSPEED
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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 usethe 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 betweenwinding-ambient model to predict the winding temperature
– but has no value set so Motor-CAD and SPEED havevery different results
– Motor-CAD predicts the thermal resistance betweenwinding and ambient to be 2C/W
SPEED / Motor-CAD Link Example
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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
SPEED / Motor-CAD Link Example
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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 transfercoefficient [W/m2/C] and the internal thermal resistanceswinding-stator and stator-housing
4. calibrate the Hot10 thermal lumped circuit (10 nodes with
convection/radiation heat transfer paths on the outside ofthe machine and internal resistances for winding-stator,winding-end winding, end winding-endcap, stator-housing, rotor-stator, etc).
G T E l (PC BDC)
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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 directequivalent in PC-BDC, housing type, bearings etc.
– intelligent geometry scaling makes sure all parts fit the size ofmachine 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)
GoTar Example (PC-BDC)
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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 coolingexist and what can be done to make the machine cooler
– Materials, mounting, improved impregnation, interface gaps, etc.
GoTar Example (PC-BDC)
T C l Fi d
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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
T C l D CW
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• Check Select/Deselect all value and press [Iterate]
• Good prediction of winding temperature
TempCalc = DegCW
T C l ThR t
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• Check Select/Deselect all value and press [Iterate]
• Good match between conductor, stator, housing and magnet temperatures
TempCalc = ThRcct
T C l H t10
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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
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
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
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
SPEED/Motor CAD Links
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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
SPEED Thermal Model Recommendations
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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 byMotor-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 invalidtemperature 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
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 thelosses 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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