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MotorSolve BLDC

DESIGN SOFTWARE FOR BRUSHLESS DC &

PMAC

PREDICTING PERFORMANCE FOR BETTER

MACHINES

DESIGNS

PMAC PREDICTING PERFORMANCE FOR BETTER MACHINES DESIGNS MotorSolve BLDC, our electric motor design software for

MotorSolve BLDC, our electric motor design software for brushless dc and permanent magnet AC machines, combines easy- to-use templates with an automated-FEA solver to calculate performance.

Most modern electric motors do not adhere to the rules of thumb and general approximations used by designers for decades. Meeting the growing demand for higher efficiency & lower costs requires software that delivers reliable results and does not give false predictions for crucial performance factors resulting in avoidable and costly complications. Only FEA simulations:

Predict performance properly when there is saturation

Account for all sources of loss such as eddy current and hysteresis

Work Flow:

properly when there is saturation • Account for all sources of loss such as eddy current

Useful Features:

Efficiency is key, that's why MotorSolve BLDC includes many automated features which reduce the time to perform each design cycle.

Mechanical Losses: friction, windage and stray

Results based on machine with ideal or non-ideal drives

Easy-to-use template interface with descriptive design parameter names and full 3D view of the machine

Automated winding configuration

Detailed end winding geometry

Accurate loss calculations

Create VHDL-AMS models of your machine for system simulations

New MotorSolve Thermal option for two-way magnetic-thermal coupling

Features:

Within a few minutes any BLDC design can be created in MotorSolve. The automated FEA feature manages the setting required to compute accurate performance results or export the design problem to MagNet for classical FEA analysis.

Template Library

Interior Permanent Magnet

Surface Mounted

Bread-loaf

Spoke

Inset

All standard slot types

Design Parameters

Geometric dimension of the magnets, teeth and slots

Number of poles and slots - can be arbitrarily large

Stack length

Lamination, coil and magnet material

Temperature for each component

Skew angles

Auto Sizing An initial value for several parameters related to the size of the machine based on:

torque per unit volume

rated current density

Winding Layout

Automatic winding layout feature

Supports several wire sizing methods

Relevant factors (winding factor, fill factor, back emf, etc) are automatically calculated

Rapid and Accurate Results

Results based on machine with ideal or non-ideal drives

Users control the level of refinement (accuracy vs time)

Lumped Parameter analysis also supported for use in equivalent circuits

Output Waveforms and Charts

Current

Back-EMF

Torque

Flux Linkage

And many more

Performance Calculations

Torque

Efficiency

Air Gap Flux

Cogging Torque

And many more

Field Plots

Demagnetization prediction

Flux density

Hysteresis, eddy current, iron and total losses

And many more

Drives Drives can be treated as either ideal or PWM, supporting both wye and delta connections.

Export

MagNet

DXF

VHDL-AMS

Summary and Report

The summary feature compares two or more designs side-by-side and highlights the differences in design data

Design parameters, performance data and summary comparisons can be added to the report form (PDF)

Analysis Types

D-Q analysis

Ideal for what-if analysis: initial sizing or design variations

Rapid: based on a single FEA simulation to characterize the performance

The component values from the equivalent circuit of the D-Q approximation can also be obtained using the lumped parameter analysis

PWM analysis

Perform a dynamic simulation of the electronic commutation in a three- phase full-bridge

Squarewave or Sinewave

Important at high speeds: current waveforms differ significantly from the ideal

Transient analysis

Perform a full time-stepping non-linear FEA simulation

Wye or Delta

Sinusoidal or six-step drive

Highly accurate for all types of operating conditions and ideal for final design verification

MotorSolve

Thermal

Option

THERMAL ANALYSIS MODULE FOR MotorSolve

IM

COMPLETE MOTOR PERFORMANCE PROFILE

BLDC

&

MotorSolve

MotorSolve Thermal is the innovative design software for analyzing the effects of heating and different cooling methods on machine performance. Using a robust and highly proficient automated 3D FEA engine, performance results can be based on steady state or transient analysis.

results can be based on steady state or transient analysis. MotorSolve eliminates the need to create

MotorSolve eliminates the need to create two separate machine models for thermal and electromagnetic analysis. Within just one design environment and using a singular machine model, you can perform both types of analysis. There is no template matching or software linking. Just specify the motor and housing geometry, winding details, losses, materials and cooling type once.

Work Flow:

linking. Just specify the motor and housing geometry, winding details, losses, materials and cooling type once.

Useful Features:

Efficiency is key, that's why MotorSolve Thermal includes many automated features which reduce the time to perform each design cycle.

Full 3D view of housing and machine model

Modern user interface

Accurately predict losses and increase your machine efficiency

No template matching: one file for all analysis types

Two-way coupling of electromagnetic and thermal simulations

All heat transfer paths are considered

Thermal analysis of your machine as a function of its drive

Easy access to solution data

Features:

MotorSolve Thermal is a 3D FEA-based analysis tool. It offers seamless co- simulation between electromagnetics and thermal physics for machine designers, all within a single interface. Multiple design scenarios can be setup, solved and post-processed in a single model file as well.

Supported Machine Types

All templates in MotorSolve BLDC

MotorSolve Thermal is an optional module which requires at least one electromagnetic analysis module. To learn more about the templates, design parameters, windings, results and other electromagnetic related topics for machines, please visit the MotorSolve BDLC or MotorSolve IM web pages.

Design Features for Thermal Analysis

Housing, bearing and shaft

Slot liner, wedge and coil separator

Detailed 3d end winding geometry

Thermal Physics Considerations

Conduction Physics

Natural & Forced Convection Physics

Radiation Physics

Cooling

Totally Enclosed Non Ventilated (TENV)

Totally External Fan Cooled [TEFC] - Forced Convection with Fluid

Contact cooling through the flange or endplate of the machine

General Capabilities

Database of materials includes coolants

Housing, shaft, end plates and bearings are included

Machine mounting

Machine orientation

Interface gaps between components (housing, core, magnets, etc.)

Calculates anisotropic thermal conductivity of the winding

Rapid and Accurate Results

MotorSolve offers two-way coupling within one software package without the need to link two separate tools or burdensome problem setup:

Calculate the steady-state temperatures using the losses from the magnetic analysis

Perform the magnetic analyses at these steady-state temperatures taking into account the change in material properties due to the change in temperatures

Automatic calculation of the heat transfer coefficients

User controlled over-ride of heat transfer coefficients

Steady State experimental conditions

Duty Cycle transient experimental conditions

Output Waveforms and Charts

Losses for thermal analysis

Temperatures for magnetic analysis

Temperature (max, min, avg) by component (winding, bearings, magnets, etc )

Duty cycle losses

Heat capacity

Heat flux

Export

MagNet

DXF

VHDL-AMS

Summary and Report

Design parameters, performance data and summary comparisons can be recorded in an experimental log or report (PDF)

Results are easily accessible either with the use of the clipboard or export functionality

The summary feature compares two or more designs side-by-side and highlights the differences in design data