CEDRAT News - N 66 - June 2014

Cogging torque computation and mesh for non-radial

electrical motors in Flux.
Sylvain Perez - CEDRAT.

ll electrical motor designers know that the computation

of cogging torque is a tricky task, particularly in 3D.
Indeed, the amplitude of this variable is almost the
same as numerical noise. In most cases, conventional mesh
methodology is not sufficient and specific methodology must
be used. At CEDRAT, thanks to its experience, the application
team has developed methodologies to successfully compute
cogging torque in most cases.
This article presents a specific mesh methodology to compute
cogging torque for 3D non-radial electrical motors.

Specific mesh methodology for nonextruded 3D electrical motor

To explain this mesh methodology, the 3D motor presented is an
Axial Flux Motor (Fig. 1). This kind of motor is generally used in
environments involving compact lengths, like elevator systems.

DD
torque [ROTOR] (N.m)
4 TORQUE_ROT
-4 TORQUE_STAT

&

Fig. 3 presents three different calculations for cogging torque
evaluation. All calculations are based on a virtual works method
but the contours under consideration are different. The first
calculation considers the contour of the sliding cylinder (blue
curve), the second the contour of the rotor and magnets (magenta
curve) and the third the contour of the stator (green curve). All
results are bad, cogging torque is not centred 0 N.m. However,
these results give us some information. We can see that cogging
torque evaluations considering stator contour are the most
accurate. This suggests that mesh is more appropriate surrounding
the stator than the rotor. For further information, we need to use
dedicated tools to perform mesh analysis.

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The specific mesh methodology is based on Flux 3D mesh tools
and some physical considerations. We will look at the various steps
to follow. The first one is the starting point, whether, a conventional
mesh imposed by Mesh Point Discretisation. Then, we will see
how to use the Flux tool for analysing mesh quality. Afterwards,
on the basis of analysis and some physics angles, we will apply a
new mesh imposed by Mesh Line Discretisation with relaxation.
Finally, we will compare results for the different meshes in terms
of Accuracy/Computation time.

Analysis of mesh defect with Flux tools

To identify where the mesh can be improved, Flux offers dedicated

tools based on error criterion calculation. In this example, cogging
torque is dependent on a derivate of co-energy that means
selecting the magnetic co-energy gradient as an error criterion
(Fig. 4).
We display error criteria on each volume element of magnets
(Fig. 5) and of the sliding cylinder (Fig. 6). The greater the number
of red spheres, the bigger the criterion error. Another important
point to consider is the density of spheres which may also offer
a good indicator.

Starting with a conventional mesh imposed by Mesh Point

Discretization
The conventional mesh method is to use discretisation imposed
by point, i.e.: imposing mesh specifications at each point of the
geometry. With Flux, we currently use this mesh method coupled
with aided mesh options. In this case, we obtained the mesh
presented in Fig. 2. From this conventional mesh with first-order
elements, computation results are given in Fig. 3.

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imposed by mesh point

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(continued on page 11)

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CEDRAT News - N 66 - June 2014

We note that the criterion error display on the sliding cylinder

indicates that bad mesh elements are only in the airgap below the
magnets. That tells us that shadow should be higher and that face
relaxation is too fast. The criterion error display on magnets is less
clear to analyse, the red sphere indicates that volume relaxation is
too high and should be reduced. We also note high sphere density
(not necessarily red ones) along magnet edges which suggests the
mesh on edges should be refined.
This information allows us defining a new efficient mesh.

Final comparison

It is important to get a good precision, bearing in mind that a good

Precision/Computation time trade-off is the objective. At this
time, we have not considered computation time, this paragraph
compares results and time computation for each mesh described
previously with first-order elements and with second-order
elements (Tab.1, Fig. 9 and Fig. 10).
DD
torque [ROTOR] (N.m)
4 TORQUE_ROT
-4 TORQUE_STAT

Define a new efficient mesh based on Mesh Line

Discretization
In the previous paragraph we highlighted the need to reduce
relaxation and increase shadow. Based on CEDRAT application
team knowledge and confirmed by the previous mesh analysis,
we can conclude that for volumes bordering the air gap (magnets
and stator tooth), mesh on edges has to be refined.
Thin mesh on edges seems to be explained by the fact that where
the magnetic flux density changes quickly, mesh has to be refined
in order to precisely compute magnetic field paths. Accordingly,
the mesh method consists of finely mesh edges of volumes next
to the air gap (Fig. 7). Results of this second mesh with first-order
elements are given by Fig. 8.

DD
torque [ROTOR] (N.m)
4 TORQUE_ROT
-4 TORQUE_STAT

&



and with second


DD
torque [ROTOR] (N.m)
4 TORQUE_ROT
-4 TORQUE_STAT

Cogging torque is centred on 0 N.m whatever the contour

considers. Even though there are some differences, the 3 cogging
torque calculations are now compliant. We can consider that the
second mesh is efficient.

&E
mesh based onMesh
W

DD
torque [ROTOR] (N.m)
4 TORQUE_ROT
-4 TORQUE_STAT

Method

Classical
mesh
New
mesh

Mesh element
order

Number of
nodes

&



and with second


Number
of volumic
elements

Computation
time

1st

8685

38270

2nd

59556

38270

10

1st

36444

174892

2nd

258699

174982

72

dD
According to Tab.1, Fig. 9 and Fig. 10, the new mesh with firstorder elements offers the best compromise between accuracy
and computation time.

Conclusion
Cogging torque computation has always been a complex exercise,
especially in 3D. Nowadays, Flux tools combined with CEDRATs
experience in this domain make life easier. In this article we have
reviewed a methodology to obtain efficient mesh for your device
to rapidly produce a reliable estimate of cogging torque.
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In a next issue we are proud to present you a new article "Cogging

torque computation and mesh for radial electrical motors".

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