Vibro Acoustic Analysis With Flux and Opti Struct FINAL

Vibro-acoustic Analysis for Noise
Reduction of Electric Machines

From Flux to OptiStruct
Example : Synchronous Machine Flux 2D coupling to OptiStruct
Patrick LOMBARD Christophe BAILLY

Application Team Manager Senior Application Engineer
Patrick.Lombard@cedrat.com bailly@altair.com
2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Introduction
Goal of this presentation : illustrate the different steps of a vibro-acoustic study of a rotating
machine with the coupling between Flux 2D/3D and OptiStruct
Content
Main steps in Flux modeling
New vibro-acoustic coupling in Flux
Steps in OptiStruct
3
Electro-magnetic analysis
4
Main Steps
Geometry Mesh Physics Solving Post-processing

Analysis on one mechanical period + Forces
Transient application computation + Visualization + Forces export
Forces import Vibratory Acoustic

Geometry Mechanical mesh
from Flux response response
OptiStruct
5
Synchronous Machine to Model - Presentation

Targeted performance
Mechanical Power Mean Value 55 kW
Rotor velocity 7500 rpm
Currents in phases Peak value (sinus wave) 70 A
Field current Constant value 10 A
6
Main Steps in Flux
Post-
Geometry Mesh Physics Solving processing
The geometry is built with Flux overlays

7
Main Steps in Flux
Post-
The geometry is ready to be meshed when we use Flux Overlays
8
Main Steps in Flux
Post-
In this section we make the following steps:

Create materials
Create circuit
Create mechanical sets
Define the different regions of the device
A Python file may be prepared with the different quantities mentioned above. These
quantities will be created automatically.
9
Main Steps in Flux
Post-
Define law of variation of parameters (solving scenario)

Solve
10
Main Steps in Flux
Post-
Open the dedicated vibro-acoustic context

Create computation support
Compute the magnetic forces and their harmonics (on the defined computation support)
Display magnetic forces and their harmonics
Export the computed magnetic forces to OptiStruct
11
Main Steps in Flux

Implementation Geometry Mechanical mesh Forces import
from Flux
Vibratory
response
Acoustic
response
1- In OptiStruct generate the mechanical support

OptiStruct
12
Main Steps in Flux

Implementation Geometry Mechanical mesh Forces import
from Flux
Vibratory
response
Acoustic
response
2- In Flux go to the mechanical analysis context

OptiStruct
13
Main Steps in Flux

Implementation
3- Import the mechanical support (.bulk)
Create 2 coordinate systems REP1 and REP2. REP1 depends on XY1 and REP2 depends on REP1
The mechanical support is imported in REP2
14
Main Steps in Flux

Implementation
4- Launch the computations
Create a computation support inside the airgap
The computation support should be on the of the airgap close to the stator when the computation is for the stator
Mechanical
Computation Support
Support
Sliding Rotor radius

Cylinder
15
Main Steps in Flux

Implementation
The computation must be launched on one mechanical period 360
In Flux we can choose to run the computation on one mechanical period or one electrical period
For example in the case of one mechanical period [60;420] corresponding to [1.333E-3 s;9.333E-3 s] we can consider only of
this period: [7.333e-3 s ; 9.333E-3 s] => [330 ; 420]
We can specify to compute only the magnetic forces or to compute magnetic forces AND harmonics
16
Main Steps in Flux

Implementation Geometry Mesh Physics Solving Post-processing
17
Main Steps in Flux

Implementation Geometry Mesh Physics Solving Post-processing
5- Visualization of the magnetic forces
18
Main Steps in Flux

Forces import Vibratory Acoustic
Implementation Geometry Mechanical mesh
from Flux response response
OptiStruct
6- Export the computed magnetic forces to OptiStruct as (*.bulk) file
19
NVH ANALYSIS
20
NVH analysis
Step to setup the NVH analysis, we can use this workflow :
1. Mesh the parts

2. Add properties material
3. Import the forces from Flux
4. Add the ERP output
5. Execute the frequency response analysis and post process the radiated surfaces
6. Optional : Use the optimization capabilities to reduce the noise of electric machines
21
NVH analysis
Mesh description :
Stator :
Isotropic material
Number of elements = 440 000
DOF = 1.6 millions
22
NVH analysis
Mechanical excitation:
The excitation are directly exported to

the OptiStruct format from the Flux
analysis
These forces are imported as an

include file
23
NVH analysis
Modal analysis :
Free-free modal analysis between 0 50 000 Hz (1.6 millions of DOF)
1075 modes (include 6 rigid body modes) in this frequency range
First elastic mode at 1045 Hz 11 elastic mode at 2788 Hz

24
NVH analysis
Modal analysis :
Free-free modal analysis between 0 50 000 Hz (1.6 millions of DOF)
1075 modes (include 6 rigid body modes) in this frequency range
The job ran on 8 CPUs : Intel Xeon CPU E5-2680 v3 @ 2.50GHz

Elapsed time = 54 minutes
Normal modes computation = 46 minutes
Data recovery (6Go) = 8 minutes
25
NVH analysis
Frequency Response analysis :
27360 nodes are excited from the Flux analysis between 0 and 31 875 Hz
Constant damping of 0.06% was defined
26
NVH analysis
ERP (Equivalent Radiated Power) output
ERP evaluation
Minimize ERP Reduction of noise and vibrations
ERP Mathematical Expression
ERPC : the speed of sound

ERPRHO : fluid density
ERPRLF : radiation loss
27
NVH analysis
Displacement result
28
NVH analysis
ERP result
29
Conclusions
30
Conclusions
The coupling between Flux 2D/3D and OptiStruct works Shapes variables example
Flux is able to export the excited load in an OptiStruct
format The import in HyperMesh is direct
The NVH analysis is managed by OptiStruct
Use the optimization capabilities to reduce the noise of

the rotating machines :
Conceptual or tuning optimization with OptiStruct
Electro-magnetic and NVH optimization with a strong
coupling with HyperStudy
31
The End
32

Vibro Acoustic Analysis With Flux and Opti Struct FINAL

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Vibro Acoustic Analysis With Flux and Opti Struct FINAL

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Verfügbare Formate

Vibro-acoustic Analysis for Noise

Reduction of Electric Machines

Example : Synchronous Machine Flux 2D coupling to OptiStruct

Patrick LOMBARD Christophe BAILLY

Geometry Mesh Physics Solving Post-processing

Forces import Vibratory Acoustic

Synchronous Machine to Model - Presentation

Main Steps in Flux

The geometry is built with Flux overlays

Main Steps in Flux

The geometry is ready to be meshed when we use Flux Overlays

Main Steps in Flux

In this section we make the following steps:

Main Steps in Flux

Define law of variation of parameters (solving scenario)

Main Steps in Flux

Open the dedicated vibro-acoustic context

Main Steps in Flux

1- In OptiStruct generate the mechanical support

Main Steps in Flux

2- In Flux go to the mechanical analysis context

Main Steps in Flux

Main Steps in Flux

Sliding Rotor radius

Main Steps in Flux

The computation must be launched on one mechanical period 360

Main Steps in Flux

4- Launch the computations

Main Steps in Flux

5- Visualization of the magnetic forces

Main Steps in Flux

1. Mesh the parts

The excitation are directly exported to

These forces are imported as an

First elastic mode at 1045 Hz 11 elastic mode at 2788 Hz

The job ran on 8 CPUs : Intel Xeon CPU E5-2680 v3 @ 2.50GHz

ERP Mathematical Expression

ERPC : the speed of sound

Use the optimization capabilities to reduce the noise of

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