Introduction to Maxwell/ Mechanical Coupling

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1 ANSYS 통합해석환경을이용한전기자동차용모터성능해석 ANSYS Korea Byungkil KIM, Soohyun PARK, Jeongwon LEE, Cheonsoo JANG* 1

2 목차 모터설계에적용되는 ANSYS 제품군역할 모터성능해석 1 : 진동 / 소음 모터성능해석 2 : 피로수명 모터성능해석 3 : 충격강도 2

3 모터설계에적용되는 ANSYS 제품역할 모터설계에서고려되어야하는기초성능 Electrical Performance Vibration and Acoustic Rear Cap & Bearing Coil Rotor & Magnet Stator Housing Front Cap & Bearing Thermal and Cooling Impact, Strength, Fatigue 3

응력산출 EM force EM loss density EM Loss Mapping EM Force Mapping Electro- Magnetics

4 모터설계에적용되는 ANSYS 제품역할 Electric Mechanical Maxwell-ANSYS Mechanical (Workbench 환경 ) One-way or Two-way 전기-열유동연성 전기-구조연성전기-열유동-구조연성해석의필요성 비대칭회전현상을고려하여신뢰성있는 Stator Tooth 응력산출 EM force EM loss density EM Loss Mapping EM Force Mapping Electro- Magnetics Temperatur e Thermal Static or Transient Temperature Stress 4 Deformed mesh EM loss distribution

5 모터설계에적용되는 ANSYS 제품역할 Electric Mechanical( 열유동 ) MAXWELL 해석산출물 자속밀도, FFT, Heat Loss Heat Loss 연계해석의필요성 영구자석은온도가높아지면감자현상으로모터효율및성능이저하됨 온도에따라재질선정 Maxwell-Fluent 연성해석을통한신뢰성있는온도예측이필요함 Convergence in 4 iterations 1st 3rd 4th 2nd Temperature Electromagnetic 5

6 모터설계에적용되는 ANSYS 제품역할 Electric Mechanical( 구조 ) 2-Way Coupling Analysis by Force Distribution Deformable Body 를이용한연성해석지원 6

7 모터설계에적용되는 ANSYS 제품역할 Electric Fluid Mechanical(Thermal Stress) Fatigue 2-Way Coupling Analysis by Force Distribution 온도구배에따른열응력및내구수명예측 7 Loss Temperature Thermal Stress Fatigue Damage

8 모터성능해석 1 진동 / 소음 : Electric-Mechanical 연성해석 8

9 모터성능해석 1 : 진동 / 소음해석 Electro Static 2D - Modal and Harmonic 3D 가진원 : Slot & Pole 조합에의한발생전자기력 Analyze natural frequencies Mapping Force Moment 9

10 모터성능해석 1 : 진동 / 소음해석 Maxwell: 2D Transient 2D 전자기장해석결과를 3D 구조해석과연계가능함 Machine Type Internal Permanent Magnet Adjustable Speed Motor Number of Poles 8 Stator Slots 48 Output Power Speed Torque 44.8kW 2,000 & 7,200 RPM 2,000 RPM 10 Efficiency 91.24%

11 모터성능해석 1 : 진동 / 소음해석 주파수응답해석 운전조건상의고유주파수와전기주파수를격리하여야함 Slot 과 Pole 설계조합으로대응 Mode 고유주파수 [Hz] 1 st nd rd th ,000RPM 7,200RPM 175Hz Mapping force & moment on Tooth Tips (48EA) Bolt MTG Fix 125Hz 11

12 모터성능해석 2 피로수명 : Electric-Fluid-Mechanical-DesignLife 연성해석 12

모터성능해석 2 : 내구수명 Analysis - Electrical Design -

13 모터성능해석 2 : 내구수명 Analysis - Electrical Design - Motor Package Mesh for Fluent Analysis - Thermal Analysis - Structural Analysis - Fatigue Eddy current 3D solver Steady-State 3D 1. One and Two way Coupling 2. Mapping : Losses - Total Losses Mapping - Body Temp Result - Thermal Stress 13 Improved Heat Sink Housing

8 Stator Slots 48 Internal Permanent Magnet Adjustable Speed Motor Core

14 모터성능해석 2 : 내구수명 Maxwell: 3D Transient 효율극대화, Total Heat Loss 최소화 온도에민감함 Efficiency Map Torque Core Loss Magnet Loss Machine Type Number of Poles 8 Stator Slots 48 Internal Permanent Magnet Adjustable Speed Motor Core Loss Map Output Power Speed Torque 44.8kW 2,000rpm 214N.m 14 Efficiency 91.24%

AVERAGED HEAT TRANSFER COEFFICIENT (W/M2)

Rotational Speed on HTC HTC vs RPM 300 250

ROTATIONAL SPEED (RPM) HTC@Stator-Parallel

15 AVERAGED HEAT TRANSFER COEFFICIENT (W/M2) 모터성능해석 2 : 내구수명 Effect of fin geometry and Rotational Speed on HTC HTC vs RPM Total Loss Mapping 200 Meshing Thermo-Fluidic Analysis ROTATIONAL SPEED (RPM) HTC@Stator-Parallel HTC@Stator-Radial HTC@Housing-Parallel HTC@Housing-Radial 15

16 모터성능해석 2 : 내구수명 Body Temperature Stress Result Direct Mapping of body temperature From Fluent to Mechanical Body Temperature Thermal Stress Result Damage 16

17 모터성능해석 2 : 내구수명 Mechanical ncode DesignLife Material Properties : Aluminum Alloy Mesh Operation S-N Curve of Aluminum Alloy Import Body Temperature Boundary Conditions : Fixed Bolt Mounting ncode DesignLife 17

297E-4 193 MPa 2.511E-5 7,200 RPM Base Design Improved Design Max.Stress Max.

18 모터성능해석 2 : 내구수명 Improved by 11% RPM 증가 - Heat Loss 10% 증가 - 열전도율 300% 증가 2,000 RPM Base Design Improved Design Max.Stress Max.Damage Max.Stress Max.Damage 217 MPa 2.297E MPa 2.511E-5 7,200 RPM Base Design Improved Design Max.Stress Max.Damage Max.Stress Max.Damage 104 MPa 1.778E-7 87 MPa 2.176E-8 Improved by 16% 18

19 모터성능해석 2 : 내구수명 효율적인연성해석프로세스제안 Need more time to do the meshing & analysis for fluid physics HTC External Data from Fluent without Fluid analysis Save Run Time and Hardware Resource! 19

20 모터성능해석 3 충격강도 : ANSYS Mechanical 20

21 모터성능해석 3 : 충격강도 Transient Structural Acceleration : 30g Stress Result Mounting Bracket Max.Stress : 275MPa 21

Study Design Variable 1 35mm 25, 30, 35 Design Variable 2 4mm 3, 3.5, 4, 4.

22 모터성능해석 3 : 충격강도 Design Variables Design Variable 1 - Rib Height Design Variable 3 - No of Ribs Design Variable 2 - Rib Thickness Design Variable 4 - Fillet Radius Design Variable 5 - Base Plate Thickness Design Initial Design Parametric Study Design Variable 1 35mm 25, 30, 35 Design Variable 2 4mm 3, 3.5, 4, 4.5 Design Variable 3 2EA 2, 3 Design Variable 4 3mm 3, 4 Design Variable 5 4mm 4, 4.5, 5 Result Initial Design Target Stress 275MPa < 200MPa (Yield Stress: 280MPa) 22

23 모터성능해석 3 : 충격강도 DOE Table No of Iterations : 10 Automatic Analysis coupled with Design Modeler Automatic Analysis For all design points Design Parameter 23

24 DOE Result 모터성능해석 3 : 충격강도 Initial Design Best Design 1 Best Design 2 Result Stress Remark Initial Design 275MPa - Best Design 1 185MPa 33% Best Design 2 199MPa 28% Weight of motor package shows little change. (about 0.09% ) 24

25 향후계획 Motor Control Electrical Performance Vibration and Acoustic Impact and Strength Design Optimization Thermal and Cooling 25

26 감사합니다! 26

KAERI/TR-2128/2002 : SMART 제어봉구동장치 기본설계 보고서

KAERI/TR-2128/2002 : SMART 제어봉구동장치 기본설계 보고서 KAERI =100,000 25 20 Force, [kn/m^2] 15 10 5 0 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 b/a I = 1500[ AT ], a + b = 16[ mm], hr = 5.6[ mm], hδ = 11.2[ mm], δ = 0.35[