SIMULATION: IMPETUS FOR PROGRESS

AS CLOSE TO THE PROTOTYPE AS POSSIBLE!

Simulation enables experimentation with a near-reality digital representation of a system. In this context, the use of simulation technologies is a strategy for finding a common path to a sustainable future.

Because the development and simulation of electric and hybrid drive systems provides sustainable support for decision-making processes prior to prototype production and physical tests: helping to keep future product and operating costs as effective as possible.

FACT CHECK

SIMULATION: THE EFFICIENCY BOOSTER

The fact is: simulation makes the development and manufacturing process of drive systems for e-cars efficient!

For the ongoing development of future-oriented e-drive solutions, CONNACTIVE has used simulation methods to calculate and analyse the physical behaviour of e-motors.

" We’ve developed a two-stage simulation process for the electromagnetic design and simulation of the electric machines and their environment ": Dagmar Münch, Chief Technical Officer (CTO) at Alvier Mechatronics.

 

  1. First we optimise the product with simulations in the nominal state at different operating points
  2. We then look at the product under the tolerances that occur in real life

SIMULATING THE BIG PICTURE

First we optimise the product with simulations in the static state. Next, we look at the product under the real-life thermal and vibration constraints.

The clear results led to an overall strategic approach:

 

  • Mechanical design
  • Electromagnetic design
  • Cooling concepts
  • Transmission design
  • Analyses of the acoustics and the NVH range (Noise Vibration Harshness)
  • Simulations used to support selection and specification of manufacturing processes

IN THE FAST LANE THANKS TO SIMULATION

From simulation to B-samples

“When designing e-motors for specific customers, we regard simulation as a central development tool that provides a reliable basis for decision-making at an early stage, makes it easier to compare numerous different alternatives and is essential for fine-tuning the selected version.”

Dagmar Münch, CTO Alvier Mechatronics.

Simulation: The spectrum

  • Mechanical and electromagnetic development and calculation of the motor using Ansys Maxwell and Ansys Mechanical
  • Thermal analyses are carried out to investigate temperature distribution due to electromagnetic losses, including electronic losses.
  • Flow analyses with Ansys Fluent to ensure sufficient cooling in all operating modes.

Focus on: Tolerances

Two different model types are analyzed
 

  • Nominal design in ideal dimensions
  • Analysis of the effect of tolerances: modified geometry with deviation of the length of stator teeth and magnets from their nominal values

SMC manufacturing process

Objective: Digital tools to ensure optimal use of the presses.

Method: Data collection on our key processes

Data: Properties of the individual components for the description of the product characteristics. These depend on the pressure at which they were compacted and the temperatures at which they were baked out.

Optimisation through simulation

Within the product development process, the team at Alvier Mechatronics uses simulation to handle the A-sample phase, so that only B-samples need to be built as actual prototypes. These are then also used to calibrate the simulation models.

 

Sustainable knowledge management

The B-samples already have a very close-to-production status, with the improved simulation models being used to further optimise the motors.
The simulation models and data are a decisive company asset and are necessary for the further development of the learning systems: they can be called up at any time and can be used at any time.

 

 

Further information about simulation: 

Benefit from added value information about new CONNACTIVE developments.

EXCLUSIVE INFORMATION

PHASED APPROACH:
Simulation in engine development in Ansys Maxwell

PHASE 1:

3D CONFIGURATION

We begin in the traditional way with the electromagnetic 3D design of the active components.


THE BASIS: the ideal case

  • typical material data
  • no fluctuations in tolerances and material properties

PHASE 2:

DESIGN OF EXPERIMENTS

We create the electromagnetic model in Ansys Maxwell as DoE: Design of Experiments.


THE REASON: evaluation of tolerances

  • identification of mechanical tolerances in stator and rotor production
  • influence of the air gap tolerances
  • simulation of the influence on the function, efficiency and acoustics of the motors

PHASE 3:

EVALUATION

We have optimised the motor design and reduced the tolerance requirements for the stator and rotor components.
 

THE BENEFIT: Simulation results

Evaluation of mechanical tolerances in stator and rotor production:

  • input variable: simulation results from Maxwell
  • transfer to Ansys Mechanical
  • Comparison of the results relating to the acoustics in VR Sound

OVERVIEW ADVANTAGES

  • High forecast quality
  • Clear time savings for test scenarios
  • Material savings through reduction of prototypes
  • Reliable estimates of product and operating costs
  • All product data at the push of a button, from the idea to the design to the final production
  • Agile intelligence: implementing insights from previous design and production experience.
Dagmar Münch Portrait

Chief Technical Officer (CTO), Alvier Mechatronics

Dagmar Münch

With the support of CADFEM Consulting, we’ve been able to acquire the simulation expertise we need in record time. On the basis of the simulation studies commissioned by us, the CADFEM specialists develop efficient concepts and approaches for calculating and analysing the physical behaviour of the electric motors.