Coupled Electromagnetic and Thermal Solution for Electric Machine Design

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1 Coupled Electromagnetic and Thermal Solution for Electric Machine Design Xiao HU Zed (Zhangjun) TANG ANSYS, INC ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

2 Introduction Electric machine design is a multi-physics problem Electromagnetic Fluid and thermal Mechanical (Stress, Vibration) Power electronics/control Electromagnetic, thermal and mechanical designs are interrelated Losses from electromagnetic design affect temperature Temperature rise will change material properties Thermal induced mechanical stress A design environment that accommodates all physics and their interaction is highly desired ANSYS Workbench environment 2009 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary

3 Simulation Driven Product Development - Electric Machine Design Methodology Much better solution with ANSYS CFD/Mechanical 2009 ANSYS, Inc. All rights reserved. 3 ANSYS, Inc. Proprietary

4 Maxwell2D for Electromagnetic Majority of Electromagnetic Designs are Done in 2D for Electric Machine >80% Faster Enough accuracy Maxwell2D Transient Solver Transient excitation Transient motion Motion induced transient effects Coupling between Maxwell3D and ANSYS is possible and follows the same design flow 2009 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary

5 Design Flow Centroids Workbench Mesher Temperature Geometry Workbench DM Maxwell UDP Maxwell Losses Mapped Losses ANSYS Mechanical (automated) ANSYS CFD (Scripted) 2009 ANSYS, Inc. All rights reserved. 5 ANSYS, Inc. Proprietary

6 Accurate Loss Coupling Most Losses are Distributed Eddy loss (PMs) Core loss (Stator & Rotor) Time Averaged Spatial Losses Time constants are very different for electrical and thermal 2009 ANSYS, Inc. All rights reserved. 6 ANSYS, Inc. Proprietary

7 Export Thermal Data to ANSYS Mechanical 2009 ANSYS, Inc. All rights reserved. 7 ANSYS, Inc. Proprietary

8 Import Maxwell Loads to ANSYS Mechanical 2009 ANSYS, Inc. All rights reserved. 8 ANSYS, Inc. Proprietary

9 Maxwell 2D ANSYS Thermal 2009 ANSYS, Inc. All rights reserved. 9 ANSYS, Inc. Proprietary

10 Mechanical Eigenmode analysis of thermal pre-stressed model with Maxwell 3D transient losses 2009 ANSYS, Inc. All rights reserved. 10 ANSYS, Inc. Proprietary

11 1.75 KHz mode results of pre-stressed structural model Thermal deformation 2009 ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary

12 Need for Computational Fluid Dynamics (CFD) CFD is the science of predicting fluid flow and heat transfer by solving mathematical equations Electric machine cooling involves fluid flow and heat transfer and thus can benefit from CFD simulation 2009 ANSYS, Inc. All rights reserved. 12 ANSYS, Inc. Proprietary

13 CFD Models for Electric Machine Conjugate heat transfer with mapped losses from Maxwell Solids with different properties Liquid or air for cooling Air trapped inside electric machine Multiple Reference Frame (MRF) used to account for rotor rotation Steady state solution with the impact of rotating rotor 2009 ANSYS, Inc. All rights reserved. 13 ANSYS, Inc. Proprietary

14 Cooling Methods for Electric Machines Forced convection liquid cooling Most effective cooling Expensive Forced convection air cooling Effective cooling Somewhat expensive Natural convection air cooling Not as effective Cheap 2009 ANSYS, Inc. All rights reserved. 14 ANSYS, Inc. Proprietary

15 Test Cases and Purposes Three test cases are conducted to see the effectiveness of cooling and different temperature and its gradient distribution Cooling Method Mesh Size (K) Case 1 Forced Water 916 Case 2 Forced Air 1007 Case 3 Natural Air ANSYS, Inc. All rights reserved. 15 ANSYS, Inc. Proprietary

16 Geometry/Mesh A sector of geometry is used Periodic boundary Hex is used in most of the regions Except for the winding and the fluid region surrounding it, etc. Forced air cooling has an air domain outside 2009 ANSYS, Inc. All rights reserved. 16 ANSYS, Inc. Proprietary

17 Loss Distribution for All Cases Spatial eddy loss distribution for the magnets Spatial core loss distribution for the rotor, stator yoke, and stator teeth Stranded winding copper loss All losses, which are highly non-uniform, are from Maxwell2D 2009 ANSYS, Inc. All rights reserved. 17 ANSYS, Inc. Proprietary

18 Temperature Distribution Max temperature are 398K, 517K, and 550k respectively Forced water cooling is the most effective and natural air cooling is the least. Forced water cooling gives similar max temperature gradient Temperature gradient is responsible for thermal stress. To keep both temperature and its gradient low is the best Forced water cooling Forced air cooling Natural air cooling 2009 ANSYS, Inc. All rights reserved. 18 ANSYS, Inc. Proprietary

19 Summary for Forced Cooling Forced water cooling is the most effective. Natural air cooling is the least effective. Forced water cooling, however, does not necessarily give the least temperature gradient. Natural air cooling may face challenge of high temperature. Forced water cooling may face challenge of high temperature gradient ANSYS, Inc. All rights reserved. 19 ANSYS, Inc. Proprietary

20 Observations about Natural Convection Cooling Natural convection Heat Transfer Coefficient (HTC) is relatively uniform compared with forced convection Natural convection cooling can be simulated by using a constant HTC instead of a full CFD calculation. Well accepted industry practice. Air trapped inside electric machines is not effective in heat transfer and thus can be removed from the calculation. Air gap kept but modeled by STILL air (details next) If air domains both inside and outside of the electric machine are removed, the problem becomes purely conductive No full CFD 2009 ANSYS, Inc. All rights reserved. 20 ANSYS, Inc. Proprietary

21 Ineffectiveness of Trapped Air Relatively low velocity and uniform temperature of the trapped air explains its ineffectiveness for heat transfer Velocity vector of trapped air (note the max velocity is only 2.5 m/s) Temperature distribution of trapped air (note the temperature scale goes from 500K to 530K) 2009 ANSYS, Inc. All rights reserved. 21 ANSYS, Inc. Proprietary

22 Test Cases Using Natural Convection Air Cooling Case 3 is from previous study and is used as a based line case here. Case 4 contains only solids Case 5 also contains the air gap between the rotor and stator to improve the accuracy. The air gap is treated as if it is solid Cooling Method Trapped Air Full CFD Air Gap Mesh Size (K) Case 3 Case 4 Case 5 Natural Air Natural Air Natural Air Yes Yes Yes 899 No No No 394 No No Yes ANSYS, Inc. All rights reserved. 22 ANSYS, Inc. Proprietary

23 Temperature Distribution Max temperatures are 550K, 566K, and 563k respectively Trapped air has minimum impact on max temperature as expected Air gap has an impact on rotor temperature distribution Air gap Full CFD (case3) Solid only, no CFD (case4) Solid and air gap, no CFD (case5) 2009 ANSYS, Inc. All rights reserved. 23 ANSYS, Inc. Proprietary

24 Comparison Max Winding Temperature (K) Error Max Rotor Temperature (K) Error Performance on 4 CPUs Case % 528 0% 4 ~ 12 hrs Case % % <10 minutes Case % % <10 minutes The full CFD case is assumed to be correct ANSYS, Inc. All rights reserved. 24 ANSYS, Inc. Proprietary

25 Summary for Natural Cooling Trapped air in general does not have significant impact on temperature distribution except for the air gap between the rotor and stator Adding a layer of STILL air in the gap can improve accuracy This could be the best comprise considering its much quicker solution than a full CFD calculation. Note that forced cooling still needs CFD due to highly localized heat transfer coefficient 2009 ANSYS, Inc. All rights reserved. 25 ANSYS, Inc. Proprietary

26 Conclusion Forced convection cooling is effective and its thermal analysis needs CFD due to highly localized heat transfer coefficient Natural convection cooling can be effectively simulated without full CFD and thus making the simulation much easier and faster Trapped air has impact on the solution only in the gap region, which can be modeled using a layer of STILL air. ANSYS CFD can be used to perform either the full CFD calculation or the simplified conduction calculation ANSYS Mechanical can be used to perform the pure conduction, thermal stress, free modal, and pre-stress modal analysis 2009 ANSYS, Inc. All rights reserved. 26 ANSYS, Inc. Proprietary

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