MotorCAD Software General Presentation 06 10 2020 1

Motor-CAD Software General Presentation 06. 10. 2020 1

Motor-CAD Ø Motor-CAD EMag, Therm and Lab modules are developed to enable fast and accurate analysis in one integrated software Ø EMag: A fast 2 D finite element module for accurate electromagnetic and electrical performance predictions. Ø Therm: Combines a lumped circuit and finite element thermal calculation for optimising the cooling system of a machine. Ø Lab: Provides efficiency mapping and duty cycle / drive cycle transient outputs within minutes Product Development Workflow 06. 10. 2020 2 2

Product Development Workflow Ø Workflow much larger topic area than detailed motor design Ø Motor-CAD useful for all areas of the workflow and not just detailed design Ø Motor-CAD used by both motor designers and application/system/test engineers Ø Automated links to other software (ANSYS Mechanical, Matlab Simulink, Optimisation) useful to speed up the workflow Motor Type & Topology + Initial Sizing Application Engineer Motor Design Engineer 06. 10. 2020 Test & Design Engineer Model Calibration Reduced Order Models & Flux Linkage/Loss Maps System Engineer Design Optimisation & Drive Cycle Analysis 3 3

Motor-CAD EMag Ø Extensive range of parametrised templates geometries with additional flexible DXF or script based geometry definition Ø Fastest FEA electromagnetic solver available as code written in assembly code Ø Smart loss calculation algorithms speed up solving – including magnet losses with segmentation and proximity losses Ø Standard or custom winding designs 06. 10. 2020 4 4

Many Geometry Types and Topologies Ø Many geometry options for components such as housings, rotors, slots, windings … 06. 10. 2020 5

Motor-CAD Therm Ø Thermal and flow network analysis of electric motors & generators Ø Network set up automatically using proven mathematics for heat transfer and air/fluid flow Ø Extensive range of cooling types Ø 18+ years of practical manufacturing experience built in to assist quantify manufacturing issues Ø Provides detailed understanding of main heat transfer paths and cooling restrictions 06. 10. 2020 6

Cooling Types Investigated Motor-CAD includes models for an extensive range of cooling types: Ø TENV: Totally enclosed non-ventilated Ø natural convection from housing Ø TEFC: Totally enclosed fan cooled Ø forced convection from housing Ø Through Ventilation Ø TE with Internal Circulating Air Ø Internal air circulating path Ø water jacket as heat exchanger Ø Open end-shield cooling Ø Water Jackets Ø axial or circumferential Ø Submersible cooling Ø Wet Rotor & Wet Stator cooling Ø Spray Cooling Ø e. g. oil spray cooing of end windings Ø Direct conductor cooling Ø e. g. Slot ducts with oil 06. 10. 2020 7

Steady-State & Transient Thermal Analysis Steady-State Temperatures and Power Flow Thermal Transient Graphs Ø We can calculate the steady-state or transient thermal performance Ø Even long and complex transients only take a few seconds to calculate 06. 10. 2020 8

Motor-CAD Integrated Thermal FEA Solver Ø Motor-CAD’s integrated FEA thermal solver allows fast calibration of the winding thermal resistance network and improved visualization of the winding hotspot location 06. 10. 2020 9

Motor-CAD Integrated Thermal FEA Solver Ø Both heat transfer and flow networks are automatically set up Ø The two networks are linked Ø MDL have improved correlations for such things as developing flow in the airgap and rotating duct pressure drop, etc. via a sponsored Ph. D Temperature rise of fluid as it passes through the cooling system 06. 10. 2020 10

Manufacturing Data Built into Models ØMany manufacturing uncertainties that affect temperature rise: Ø Ø Ø Goodness of effective interface between stator and housing How well the winding is impregnated or potted Leakage of air from open fin channel blown over machines Cooling of the internal parts in a TENV and TEFC machine Heat transfer through the bearings … etc. ØTest program over 18+ years, developing data to quantify such issues: Ø Set default parameters in Motor-CAD giving good level of accuracy without the user having done extensive calibration using testing of their own machines Ø Also automated choice of model type to give high accuracy Equivalent interface gap that is useful to non heat transfer specialist as easy to visualise Interface resistance and conductance data that is suitable for thermal experts Example of assistance given to set stator lamination to housing interface thermal resistance 06. 10. 2020 11 11

Motor-CAD Lab: Efficiency Map Calculation Fast Calculation of Efficiency Maps and Losses Facilitates very fast and accurate calculation of the motor electromagnetic and thermal performance over the full torque/speed envelope by use of intelligent loss algorithms Ø Suited to applications such as traction applications that have complex duty cycle loads Ø Automated calculation of optimum phase advance angle for maximum torque/amp or maximum efficiency control Ø Efficiency map with drive cycle overlaid 06. 10. 2020 Temperature v Time for a particular drive cycle Loss v Time calculated from efficiency map to be input into thermal model 12

Motor-CAD Lab: FEA Mapping Model Ø Flux linkage and losses calculated using FEA method at certain current and phase advance values Ø Gives an accurate calculation of the iron losses over the full torque/speed graph 06. 10. 2020 13

Motor-CAD Lab: Thermal Envelope Ø In addition to thermal transient performance prediction we can also predict thermal envelope Ø Continuous envelope calculated for a maximum winding and magnet temperature Ø Peak envelope considers temperature rise over a fixed period of time Ø e. g. 2 mins. from ambient Ø We can also plot the duty cycle operating points on the diagram 06. 10. 2020 14

Examples of Traction Motors in Motor-CAD Ø Can model all common EV traction motors types in Motor-CAD Ø Leaf, Volt, Tesla, Formula-E, …. Ø Different winding types Ø Distributed, Tooth Wound, Bar/Hairpin, Litz … Ø BPM, Induction, Synchronous Reluctance Ø Different Cooling types Ø Air, Water Jacket, Rotor Fluid, Slot Oil, Oil Spray, … 06. 10. 2020 15