Electric Machine Noise and Vibration Assessment Using MASTA / Flux

Digital Twin is enjoying a breakthrough, fueled by advances in the sophisticated use of physics-based simulation models of varying fidelities. Connected and informed by data from the field with the help of artificial intelligence, Leonardo S.p.A. validates the performance of product systems virtually in the early stages of design to accelerate the development of their next generation of products.

Dactem (a DAM group company), developer of specialist test, measurement and assembly solutions for the aerospace industries, presents an overview of the optimization of a thrust balance used for accurate measurements in electrical thruster qualification endurance testing. The presentation will provide details on how a Multiphysics simulation approach was used to find the optimum design taking mechanical, thermal and electromagnetic performance into account. Speakers: Emmanuel Pouleau, CEO, Dactem (a DAM Group company) Pierre Moutet, Engineer, Dactem (a DAM Group company) Duration: 15 minutes

Electrification is everywhere! It brings energy efficiency into systems and also helps add new smart functionalities to products. The electric motor is a key element of such systems, converting electricity into mechanical power. It is multiphysics by nature. Electric machine engineers need to take into account various constraints from the early stage of the design, looking at electromechanical performance, as well as respecting thermal and NVH constraints. Simulations need to integrate these multiple physics and also coupling effects. Dedicated tools and streamlined multiphysics workflows are developed in order to reduce complexity and speed up the design. Speakers: Limin Huang, Electromechanical Engineer, Altair Samia Saaidi, Senior Technical Specialist - Electromechanical Solutions, Altair Duration: 20 minutes

This presentation is an overview of Rizel Automotive’s R&D journey towards developing an efficient and cost-effective Motor Platform with optimum characteristics for the automotive EV Space using Altair’s tools to solve electromagnetic, structural, NVH, and Thermal challenges and validate the Digital Designs and through Physical Testing. All the way through the design process, Altair tools helped us in solving the complex problems which solve the core electric motor problems; like inductances calculation, cogging torque optimization, D axis conditioning, model analysis, transient thermal analysis which helped us in understanding and validating our analytical design and research. With the help of Altair tools, we were able to implement and validate our novel ideas related to thermal design and come up with a unique motor architecture without compromising on electromagnetics. In this process, we have designed one of the lightest and compact radial flux motors in the industry. Easy to use software from Altair, with a simple interface and automation tools; helped us to iterate, fine-tune our motors with high accuracy and a much quicker pace. And helped us to engineer a powerful yet silent and cooler but efficient motor. From our recent dyno testing at ARAI, we were able to match the simulated data to dyno test results with a deviance of less than 5%, giving us great confidence in our Simulation Techniques and Altair’s tools, helping us decrease the Time to Enter the Market.

Sustainable designs last longer. David Yáñez from Vortex Bladeless, a Spanish start-up, shares his vision of the technology, the strategies used for the integration of the different physical phenomena involved in the simulation-driven design, and the development of their resonating structures having minimal parts susceptible to wear by friction. The simulation results from CFD, with fluid-structure interaction, and electromagnetic field simulation are compared with experimental wind tunnel results and from in-service environments.

The ever-advancing digitization is being driven by the convergence of simulation, data, and HPC. While virtual methods, interoperable tools, and standardized interfaces become state of the art, the engineers and their management will play a significant role to break down silos and benefit from a Digital Thread. In this fireside chat, we will discuss the importance of people to unleash the potential of Digital Twins, how they can combine the different fields of product development and what is still missing to make the connection.

Mayer & Cie. GmbH & Co. KG sets simulation as a central element of the digital development strategy and leverages virtual product development for more efficient machine generations. Marcel Wohlleb presents simulation applications and illustrates how customers of the world market leader in circular knitting benefit.

A recording of the electric motor development panel discussion as part of the ATCx Electric Powertrain virtual event in March 2021. The panel features insight from Cleef Thackwell, Lead Motor Design Engineer at Jaguar Land Rover; Dr. Lars Fredriksson, VP Global Automotive at Altair; James Eves, Team Manager at Altair; Jonathan Stevens, Senior Development Engineer at Equipmake; Andy Jones, Innovation Program Manager at HiETA Technologies; Sergi Riba, Design Engineer at Safran Ventilation Systems; and Vincent Leconte, Senior Director of Global Business Development, Electromechanical Solutions at Altair.

Dr. Lars Fredriksson, VP - Simulation Driven Innovation at Altair, presents the multi-physics design of e-motors with a particular focus on optimising performance including efforts to maximize torque and power under defined driving conditions while keeping rotor stresses, motor vibrations and motor temperature within certain limits. We’ll also see some specific examples of this process as applied to e-motor development at both Porsche and AMG.

James Eves, Team Manager at Altair, Jonathan Stevens, Senior Development Engineer at Equipmake and Andy Jones, Innovation Program Manager at HiETA Technologies, discuss AMPERE, a joint project to produce an extremely lightweight, efficient but low-cost electric motor with an extremely high continuous power density. The consortium will present some of the engineering challenges that designing such a high performance motor has posed, and how these challenges have been overcome through advanced manufacturing technology and simulation driven design.

Sergi Riba, Design Engineer at Safran Ventilation Systems, with a brief introduction by Vincent Leconte, Senior Director of Global Business Development - EM Solution at Altair. Together they discuss the development of electric machines for the aerospace sector.

Dr. Royston Jones, CTO and Dr. Anthony Hahnel, Technical Director, give their keynote presentation during the ATCx Driving Innovation in Electric Powertrain 2021.

Altair’s portfolio of simulation-driven design solutions covers – amongst many other disciplines – electromagnetics (EM) and electronic design automation (EDA).

Vincent Leconte, Director of Business Development - EM Solutions at Altair presents at the 2019 UK e-Mobility Seminar. Optimization of e-Motors, Case Studies: Jaguar Land Rover & Porsche. Cooling Simulation of the eMotors.

Electrification is one of the main means of creating a low-carbon economy, allowing to use renewable energies and energy efficient technologies. Electric power enters many industries and also impacts our everyday lives, especially with the electric mobility. The use of power electronics and control systems allows offering better reliability, safety and low maintenance costs, and also brings additional innovative functions. Learn how Altair simulation and optimization tools can help designing highly efficient electric machines, as well as advanced control strategies to help you build innovative and energy efficient electric solutions.

This presentation introduces an application of a unique, highly automatic, multi-physics design strategy for E-motors, based on a current program at Mercedes-AMG GmbH. The strategy considers essential development requirements including electromagnetics and thermal requirements, NVH, stress and durability. It accommodates for DOE, multi-objective optimization and design exploration methods to be used to explore and find feasible motor designs. The presentation will show how the strategy adds efficiency to the E-motor development process and how it impacts the total costs of development.

The Altair Multiphysics platform provides a broad portfolio of solvers and tools to help engineers develop e-motor design requirements by using simulation and optimization methods. This presentation provides examples, using Altair Machine Learning and optimization solutions, of the e-motor requirements by leveraging in data available, which is key for e-motor designers to reduce time-to-market.

This presentation demonstrates Altair’s capability of simulating the behavior of a mechanically damaged battery from a cell to a pack integrated in a vehicle, based on collaborative research previously conducted with MIT. An innovative approach of applying electromagnetics loss to predict rising temperature due to short circuit effects during an impact is discussed, along with the development of a software tool, Battery Design, which enables OEMs and suppliers to design battery applications using multiphysics optimization, including mechanical-electrical-electrochemical-thermal behaviors.

The rollout of 5G technology is going to be a boon across many industries globally, with the expansion of IoT and connected devices, and where lower latencies are opening the door to time-critical areas like autonomous vehicles, industrial IoT and healthcare. In this presentation we will share new applications and use cases from different major verticals, showing how organizations are designing innovative products using Altair electromagnetic simulation solutions related to antennas, wave propagation modelling, radio network planning and EMC applications. We will also talk about new solutions we have recently launched, and about what is available and coming in 5G.

Presentation by Koby Ingram, Gevasol BV. Conceptual Design and optimization of an Electric Motor using Altair Flux and HyperStudy. The customized electric machine with high level demands and efficiency is a challenging topic requiring top level of expertise and best in class simulation tools. This work focuses on the usage of Flux and Hyperstudy as tools for bettering the design and design process of e-motors. Presentation at the ATCx in Israel, Netanya on October 30, 2019.

Presenter: Rajiv Rampalli, Sr VP in HyperWorks Core Development team, Altair

Altair’s products for multi-body system simulation (MBS) – MotionView, MotionSolve, and Inspire Motion – form a key component of multi-disciplinary system simulations. In this presentation, we will look back on several achievements this year, in the form of customer successes as well as recent enhancements to these products which significantly extend the depth and breadth of capabilities. Some of these application examples also involve connections from MBS to other Altair technology or to 3rd-party technology such as to Altair OptiStruct (for flexible bodies and light-weighting) and Altair Activate (for hydraulics) and EDEM (for discrete element modeling of bulk materials).

Presenters: Ulrich Marl, Key Account Manager for Electric Vehicle Motor-Feedback Systems, Lenord+Bauer & Andy Dyer, MBD Sr Technical Specialist, Altair

This presentation shows a modeling process to quantify the position/speed sensor (e.g, encoder) effects on an e-motor, and corresponding control system for a concept traction motor similar to the Nissan Leaf. The integrated solution of the e-drive is carried in Altair Activate as a system builder, using other Altair solutions e-motor solutions in FluxMotor and Flux to generate data for the e-motor itself, as well as the optimal current values for the Field-Oriented Contoller. The inverter is driven with efficient space vector pulse width modulation. The integrated solution also supports different levels of modeling fidelity for the system components, for example for the e-motor where either direct co-simulation with Flux for detailed finite element analysis or a reduced order model (ROM) using look-up tables. In this way, sensor design parameters can be evaluated within an accurate system of the e-drive to improve performance and efficiency.

As more products enter the market that simulate real world experiences, consumers' expectations are rapidly increasing. To meet these rising expectations the hardware and controls required are becoming more complex while maintaining time to market and cost. To achieve this, efficiencies are required in the control’s development and hardware tools chains. Wahoo Fitness and Altair collaborated to create the new Wahoo KICKR Bike utilizing a Model-Based Design approach to controls development combined with a simulation driven design process to meet the high expectations of the bike trainer community.

Achieving the targeted brand image in a short development cycle time with minimal or zero prototypes is a major challenge faced by EV companies. To overcome this challenge, Altair, HBK and Romax have jointly developed a simulation driven process coupled with capabilities to virtually experience the noise and vibration characteristics, giving engineers a way to obtain real time performance feedbacks as the vehicle is being developed. This joint presentation on the proposed NVH development process covers a wide range of topics, including benchmarking, target setting, full vehicle and motor gearbox simulation loadcases, troubleshooting, optimization and stochastic analysis, and playback of simulation results for subjective evaluations, with a number of new technologies representing the global best practice in sound and vibration design and development. Join us to explore ways to control the sound and vibration characteristics of the vehicle, achieve the right sound, and avoid common NVH pitfalls, while accelerating time to market utilizing and experiencing virtual NVH prototypes.

David Yáñez presents at the UK ATC 2019. Vortex Bladeless is a Spanish start-up that is developing a new wind energy technology. Its key characteristic is the minimization of mechanical elements that can be worn by friction. In the first stage, its application area seems to be distributed energy. For its development, CFD tools are being of vital importance. Both the fluid-structure interaction and the behavior of the magnetic fields in the alternator are being studied mainly with this type of tool. The results obtained are being contrasted with experimental results obtained both in wind tunnel and in real application environments.

A general vision of the technology, the strategies used for the integration of the different physical phenomena involved and the path traveled for its development will be exposed.

This presentation was given on April 11, 2019 at ATCx Electromechanical Applications in Troy, MI.

This presentation was given on April 11, 2019 at ATCx Electromechanical Applications in Troy, MI.

This presentation was given on April 11, 2019 at ATCx Electromechanical Applications in Troy, MI.

This presentation was given on April 11, 2019 at ATCx Electromechanical Applications in Troy, MI.

This presentation was given on April 11, 2019 at ATCx Electromechanical Applications in Troy, MI.

This presentation was given on April 11, 2019 at ATCx Electromechanical Applications in Troy, MI.

This presentation was given on April 11, 2019 at ATCx Electromechanical Applications in Troy, MI.

Presentation by Vincent Leconte, Senior Director of Global Business Development - EM Solution at Altair.

Presentation by Virgiliu Fireteanu, Professor at Politehnica University of Bucharest.

Study based on Flux3D FE models of the influence of stator short circuit, broken rotor bar, and rotor eccentricity on EM torque and rotor unbalanced force in induction motors

Presentation by Loic Rondot, Sensor Modeling Expert at Schneider Electric.

The current sensors modeling is a real numerical challenge for electromagnetic modeling software. Physics is well mastered, but the accuracy expected for the crosstalk computation is generally crippling to use a commercial software. Recently Altair has developed, in collaboration with an academic partner (G2Elab), a new solver that uses on integral volume methods. This new solution, Modeling of Interconnected Power Systems (MIPSE), is very relevant for the current sensors modeling for both volume coils and wire coils.

Presentation by Jose Viyeira, R&D Project Engineer at Vortex Bladeless.
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Vortex Bladeless is developing a technology that extracts energy from the wind thank to Vortex Shedding and Vortex Induced Vibrations (VIV). Among others, the main fields of investigation we are working on are CFD, FEA and Electromagnetic Interactions. Within our technology, these fields are all connected, so one affects the others. For that, Altair’s suite software is helping us not only to understand the phenomena. It is so important that we consider Altair as a part of the process of maturation of the technology.

This technical session focuses on design in electrical engineering, and especially on low frequency electromagnetic simulation. Presentations can be viewed of the latest advances in the Altair simulation solutions - Flux and FluxMotor. Several companies also illustrate how they use these tools to create innovative products. In particular, it is shown how multiphysics approaches consider the various constraints of electric machine design. It is also demonstrated how optimization techniques can be used at various stages of the process, and how powerful they are to meet the many challenges of electro-mechanical design.

Presentations recorded at the 2018 Global ATC in Paris, France on October 18, 2018.

Altair’s low-frequency electromagnetic and thermal software, Flux™, offers a complete range of modeling tools able to take into account model specifications and streamline the design process. Capitalizing on 36 years of innovation in the global context of design optimization and time-to-market reduction, our solution suite is built to assist you. The ATCx Flux™ seminar is an excellent opportunity to discover the latest developments in this best-in-class software. Industry experts will present the latest capabilities and enhancements of Flux™ 2018 - providing a comprehensive view of methodology used for the analysis, design and optimization of modern applications. Presentation recorded in Troy, MI during ATCx Flux 2018 on March 14, 2018.

Altair’s low-frequency electromagnetic and thermal software, Flux™, offers a complete range of modeling tools able to take into account model specifications and streamline the design process. Capitalizing on 36 years of innovation in the global context of design optimization and time-to-market reduction, our solution suite is built to assist you. The ATCx Flux™ seminar is an excellent opportunity to discover the latest developments in this best-in-class software. Industry experts will present the latest capabilities and enhancements of Flux™ 2018 - providing a comprehensive view of methodology used for the analysis, design and optimization of modern applications. Presentation recorded in Troy, MI during ATCx Flux 2018 on March 14, 2018.

Altair’s low-frequency electromagnetic and thermal software, Flux™, offers a complete range of modeling tools able to take into account model specifications and streamline the design process. Capitalizing on 36 years of innovation in the global context of design optimization and time-to-market reduction, our solution suite is built to assist you. The ATCx Flux™ seminar is an excellent opportunity to discover the latest developments in this best-in-class software. Industry experts will present the latest capabilities and enhancements of Flux™ 2018 - providing a comprehensive view of methodology used for the analysis, design and optimization of modern applications. Presentation recorded in Troy, MI during ATCx Flux 2018 on March 14, 2018.