Electrical Machines with ANSYS

Salvador Magdaleno Adame

 ANSYS Background
In 1963, Dr. John A. Swanson
worked at nuclear laboratories of
Westinghouse in Pittsburgh, PA.

Swanson was responsible for the

analysis of nuclear reactor along
with all its components.
Computer code used to predict
the rotor stress curves of a
reactor, which was affected by
pressure and temperature.

Westinghouse was the first

customer using ANSYS.

13/02/2015 Prohibida su reproduccin o distribucin 2

 ANSYS Company
ANSYS, Inc., founded in 1970.

ANSYS develops, markets and

provides engineering support
through simulation software to
predict how particular product and
will react under a real environment.

ANSYS, Inc. is a software for

simulation applied to Engineering. It
is developed to operate under the
Finite Element Method (FEM)
theory.

13/02/2015 Prohibida su reproduccin o distribucin 3

 Industries Using ANSYS Products

Electrical Mechanical
Electronics Sports
Energy Medical
Aeronautics Communications
Aerospace Maritime
Automotive Construction
Oil and Gas Military
Nuclear, etc.

13/02/2015 Prohibida su reproduccin o distribucin 4

 ANSYS in Electrical Machine Industry
Induction machines
Single-phase motors
Three-phase motors
Wound-rotor motors and
generators
Synchronous machines
Line-start PM motors
Salient-pole motors and
generators
Non-salient pole motors and
generators
Brush commutated machines
DC motors and generators
Permanent magnet DC motors
Universal motors
Electronically commutated
machines
Brushless DC motors
Adjustable-speed PM motors and
generators
Switched reluctance motors
Claw-pole generators
13/02/2015 Prohibida su reproduccin o distribucin 5
 Finite Element Simulations in the
Electrical Machine Industry
FE simulations has become very important for
the Electrical Machine Industry due to the
requirements of customers, standards, etc.

13/02/2015 Prohibida su reproduccin o distribucin 6

Design Review
 ANSYS goals in the Electrical
Machine Industry
Avoid failures
Check and approve
designs
Development of new
technology
Demonstrate quality of
products
Be competitive and
expand market
Save costs and materials
Short delivery times
Produce patents
13/02/2015 Prohibida su reproduccin o distribucin 7
 Success Story

The use of ANSYS multiphysics tools helps

WEG to deliver best-in-class performance for
electric motors while substantially reducing
the lead time and cost of the product
13/02/2015
development process. Prohibida su reproduccin o distribucin 8
Virtual prototype Final product
 ANSYS Products for Electrical
Machines
ANSYS Maxwell
RMxrpt
ANSYS Mechanical
ANSYS CFD
ANSYS Simplorer

13/02/2015 Prohibida su reproduccin o distribucin 9

 ANSYS Maxwell
(Electromagetics)
Magnetic:
o Magnetostatics
o Time-Harmonic analysis
(eddy current analysis)
o Transient analysis

Electric:
o Electrostatics analysis
o DC conduction analysis
o Electric Transient analysis

13/02/2015 Prohibida su reproduccin o distribucin 10

 ANSYS RMxprt

13/02/2015 Prohibida su reproduccin o distribucin 11

 Electrical Machines in ANSYS RMxprt
Induction machines
Single-phase motors
Three-phase motors
Wound-rotor motors and generators
Synchronous machines
Line-start PM motors
Salient-pole motors and generators
Non-salient pole motors and
generators
Brush commutated machines
DC motors and generators
Permanent magnet DC motors
Universal motors
Electronically commutated machines
Brushless DC motors
Adjustable-speed PM motors and
generators
Switched reluctance motors
Claw-pole
13/02/2015
generators Prohibida su reproduccin o distribucin 12
ANSYS RMxprt in ANSYS Maxwell

13/02/2015 Prohibida su reproduccin o distribucin 13

 Arbitray Winding Configurations

13/02/2015 Prohibida su reproduccin o distribucin 14

 Typical Results of ANSYS RMxprt

13/02/2015 Prohibida su reproduccin o distribucin 15

 ANSYS Mechanical
(Structural and Temperature)
Structural:
o Static Analysis
o Modal Analysis
o Transient Analysis
o Harmonic analysis
o Buckling Analysis
o Random vibration analysis
o Spectrum analysis
o Substructuring analysis

Thermal:
o Steady state thermal analysis
o Transient thermal analysis
o Conduction
o Convection
o Radiation
o Phase change
13/02/2015 Prohibida su reproduccin o distribucin 16
 ANSYS CFD
(Fluid Dynamics)
o Steady-state flow o Conduction
analysis o Convection
o Transient flow o Radiation
analysis o Phase change
o Incompressible flow o Combustion
o Compressible flow o Cavitation
o Natural convection o Chemical reaction
o Heat transfer o Acoustics
o Turbulence o Particle tracking
o Steady state thermal
analysis
o Transient thermal
analysis

13/02/2015 Prohibida su reproduccin o distribucin 17

 ANSYS Simplorer
(Electrical Circuits, Block Diagrams, State Machines)

Three Basic Simulation Types:

o Circuits
o Block Diagrams
o State Machines
Multi-domain simulator for electrical,
magnetic, mechanical, fluid, and thermal
systems
Integrated analysis with EM tools
(Maxwell) and thermal tools (ANSYS
Mechanical, ANSYS CFD)
Co-simulation with ANSYS Maxwell and
Simulink
Optimization and Statistical analysis
VHDL-AMS
13/02/2015 capability Prohibida su reproduccin o distribucin 18
 Electrical Machine Design Suite

13/02/2015 Prohibida su reproduccin o distribucin 19

13/02/2015 Prohibida su reproduccin o distribucin 20
 Demagnetization Cover vibration Density
magnets modes
Magnetic flux density Currents

vibration

Losses in stator
Cooling system

Stator
Winding Rotor stress
capacitance

Losses in bars
of rotor
Magnetic flux
13/02/2015 Prohibida su reproduccin o distribucin Rotor windings 21
Losses in windings Temperature in stator temperature
 Multiphysics Process of ANSYS
in the Electrical Machine Industry

ANSYS family of products

Electro-mechanical CAD Files Ansys Maxwell ANSYS Workbench

(electromagnetics) (Mechanical, Thermal, CFD, etc)
design
coupling

Parametric
Optimization
Traditional workflow Finite element validation & optimization

13/02/2015 Prohibida su reproduccin o distribucin 22

 Representation of a
Simulation Process Cycle in Industry
Approving or
calibrating Modeling
results

Design

Engineering Pre-
Validation Simulation processing

Post- Solution
processing
13/02/2015 Prohibida su reproduccin o distribucin 23
 Testing Results
The final step of the electrical
machine:
o Laboratory tests
In laboratory tests one can measure
several variables that are of major
interest for designer and costumer

The measurements are important to

test the results obtained during the
iterative process (ANSYS-design)

Furthermore measurements can

help to calibrate" the finite element
models of future designs of
transformers
13/02/2015 Prohibida su reproduccin o distribucin 24
 Auxiliar Tools for Testing
o Fiber Optic Sensors:
Temperature:
Rotor windings
Stator windings
Structural parts
(covers, casing, etc)
Stator laminations
Rotor laminations

Pressure
Linear Displacement
Strain, Force, and Load

o Thermocouples:
Temperature:
Windings
Structural parts
Pressure
Linear Displacement
Strain, Force, & Load
13/02/2015 Prohibida su reproduccin o distribucin 25
 More Auxiliar Tools
o Thermistors:
Temperature:
Rotor windings
Stator windings
Structural parts (covers, casing, etc)
Stator laminations
Rotor laminations

o Infrared Cameras:
Temperature

13/02/2015 Prohibida su reproduccin o distribucin 26

 More Auxiliar Tools Cont
o Anenometer:
To measure velocities
Air

13/02/2015 Prohibida su reproduccin o distribucin 27

 APPLICATIONS OF ANSYS IN
ELECTRICAL MACHINES

13/02/2015 Prohibida su reproduccin o distribucin 28

 Electromagnetic and Thermal Analysis of
a 50 kW Interior Permanent Magnet Motor
(Water-Cooled)

13/02/2015 Prohibida su reproduccin o distribucin 29

 Electromagnetic Analysis of a 11 kW
Induction Motor

13/02/2015 Prohibida su reproduccin o distribucin 30

 Cooling System with Air and Water

13/02/2015 Prohibida su reproduccin o distribucin 31

 Core Losses in Stator and Rotor

13/02/2015 Prohibida su reproduccin o distribucin 32

 Stress Analysis of End Thermo-Plastic Cover of
Motor Casing

13/02/2015 Prohibida su reproduccin o distribucin 33

 Eddy Current Losses and Temperature in
End-Shield and Frame of a 2.25 MW Induction Motor

13/02/2015 Prohibida su reproduccin o distribucin 34

 Electric Fields in Slot Windings of Stator

13/02/2015 Prohibida su reproduccin o distribucin 35

 Analysis of a Fan System

13/02/2015 Prohibida su reproduccin o distribucin 36

 Thermal Analysis of Motor Casing
(Optimization of Fins)

13/02/2015 Prohibida su reproduccin o distribucin 37

 Cooling System Analysis
(Optimization of Fan Cowl)

13/02/2015 Prohibida su reproduccin o distribucin 38

 Mechanical Analysis of End-Shields Supports

13/02/2015 Prohibida su reproduccin o distribucin 39

Mechanical Analysis of Auxiliary Terminal Boxes

13/02/2015 Prohibida su reproduccin o distribucin 40

 Optimization of Motors with Fans
(Blades)

13/02/2015 Prohibida su reproduccin o distribucin 41

 Design of Variable-Frequency Drive

13/02/2015 Prohibida su reproduccin o distribucin 42

 Design of Motor Starters

13/02/2015 Prohibida su reproduccin o distribucin 43

 I am looking forward to work with
you!
If there are any questions, please contact me:

M.Sc. Salvador Magdaleno-Adame

Expert in Transformers and Electrical
Machines with ANSYS
Tel. 01 (415) 1520 547
Cel. (045) 3521087073
salvador.adame@grupossc.com
smagdalenoa@hotmail.com
13/02/2015 Prohibida su reproduccin o distribucin 45