2008 International ANSYS Conference. TEFC Electric Motors: CFD-Based Design Validation

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1 2008 International ANSYS Conference TEFC Electric Motors: CFD-Based Design Validation Cassiano A. Cezário, M.Sc. Researcher WEG Electric Equipment Motors Amir A. M. de Oliveira Jr., Ph. D. Professor Federal University of Santa Catarina - Brazil 2008 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

2 This is WEG - Foundation Werner Eggon Geraldo September 16 th, 1961 Jaraguá do Sul - SC - Brazil Capital US$ 12, = 3 VW Beetle *WEG in german means way ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary

This is WEG After 47 years - Exports since 1970 - Sales to 5 Continents (100 Countries) - Branches abroad: USA, Mexico, Argentina, Venezuela, Belgium, Germany, France, Spain, England, Sweden, Italy,

4 This is WEG After 47 years - Exports since Sales to 5 Continents (100 Countries) - Branches abroad: USA, Mexico, Argentina, Venezuela, Belgium, Germany, France, Spain, England, Sweden, Italy, Portugal, Japan, Australia, Chile, Colombia, India, China, Singapore and Emirates. - Seven plants in the exterior: Argentina, Mexico, Portugal, India and China. -Exportation: 39 % of the income -Employees 2008: (estimated) Income 2008: US$ 3,34 Billion (goal) 2008 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary

Function of Electrical Motors Function: Convert Electrical Energy in

Automatic hot wire anemometer system 2008

8 Evaluation of Fan System - Internal How to evaluate the internal fan system in a electric motor? Problems: - Difficult to access; - Risk of electrical shock; - Difficult to do qualitative analysis ANSYS, Inc. All rights reserved. 8 ANSYS, Inc. Proprietary

Evaluation of Fan System - Internal Alternatives? Use of Numerical Softwares CFD.

Data Acquisition (Air Flow) TSI Hot Wire Anemometer, model 8465. 0.

Measurement Interval Mean Air Velocity Min. Air Velocity Max.

11 Data Acquisition (Air Flow) TSI Hot Wire Anemometer, model mm Mechanical Pencil Data Acquisition Software (in house) Measurement Interval Mean Air Velocity Min. Air Velocity Max. Air Velocity 2008 ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary

12 Measurement Points (Air Flow) Example of Radial Points (RD-005-X and RD-095-1) 140 mm 100 mm Example of Axial Points (AR-100-X and AR-140-X) 2008 ANSYS, Inc. All rights reserved. 12 ANSYS, Inc. Proprietary

Data Acquisition (Fan Consumption) Special Device Auxiliar Electric Motor

18 Simulation Domain Stationary Domain Rotating Domain Additional data: steady state regime, stage interfaces, convergence criteria (rms) 2008 ANSYS, Inc. All rights reserved. 18 ANSYS, Inc. Proprietary

Steady State Results (non converging) Iteration 299 Iteration

Differences Between Domains Residual Values Temporal Average Velocity Monitoring Temporal Mean Steady State (Stage) Transient (Frozen Rotor)

24 Differences Between Domains Residual Values Temporal Average Velocity Monitoring Temporal Mean Steady State (Stage) Transient (Frozen Rotor) Additional data: transient regime, frozen rotor interfaces, convergence criteria (rms) 2008 ANSYS, Inc. All rights reserved. 24 ANSYS, Inc. Proprietary

Air Flow Error @ 3600 rpm 2008 ANSYS, Inc.

Air Flow Results @ 1800 rpm 2008 ANSYS, Inc.

Fan Energy Consumption Additional data: - steady state regime; - stage interfaces; - convergence

Fan Energy Consumption (Simulation) Additional data: - Shell script and 400

35 Conclusions and Next Steps The methodology used allowed to address efforts to the aspects related to numerical problems, eliminating uncertainties due to the geometric aspects. As a result, the numeric parameters that are essential for the study of the internal air flow of electric motors were obtained. This work discussed the problem of numerical convergence and proposed a methodology to deal with this situation. Once defined the numerical methodology, it was possible to continue with the optimization problem. The SST turbulence model, allied with the automatic wall function model, resulted in good agreement between numerical and experimental analyses, not only regarding to the punctual comparisons of the air speed, but also the power consumption of the external fan system. Next Step: Include heat transfer and optimization processes ANSYS, Inc. All rights reserved. 35 ANSYS, Inc. Proprietary

36 Acknowledgment The authors want to thank: WEG, for the support and testing facilities; ESSS (Engineering Simulation and Scientific Software), for the support to ANSYS-CFX; Mr. Regis Ataides for having made feasible this presentation; ANSYS for the invite. THANK YOU! 2008 ANSYS, Inc. All rights reserved. 36 ANSYS, Inc. Proprietary