Automotive Engineering - May 2021 - 23
ELECTRIFICATION | SIMULATION FEATURE
Simulation is a critical tool for e-machine design and analysis.
Iron loss distribution with (from left) 1-mm-, 2-mm-, and 3-mm-thick iron.
widening the yoke or perhaps introducing rounds or
fillets at sharp corners.
In this example, we vary the thicknesses of the rotor
and stator iron and examine its influence on rotor torque.
From the average torque curve shown in the previous
section, the initial rotor angle of 20° corresponding to
the positive maximum is chosen for this study. The graph
given (left) shows the torque waveforms for different
iron thickness values. The surface plots of the magnetic
flux density for the three thickness values can be used to
inspect the iron utilization and correlate them with the
corresponding torque waveforms. It can be inferred from
the plots that optimal iron utilization occurs when the
iron thickness is 2 mm (.07 in.). When the thickness is
less than 2 mm, torque reduces. If the thickness is more
than 2 mm, the extra material adds unnecessary weight,
and adds to the cost of the motor, while still generating
the same torque value.
That is not the complete picture, however. While determining iron
thickness, factors including mechanical strength and electromagnetic losses also play an important role. We can also evaluate the
effect of varied iron thickness on iron losses (above), while analyzing the flux density and EM torque. COMSOL Multiphysics has a
Loss Calculation feature that can be used to easily compute copper
losses and iron losses via the Steinmetz equation, the Bertotti formulation, and a loss model defined by the software user.
Probing the air gap MMF wave in a PMM-type electric machine
helps gauge the impact on generator power quality or motor efficiency. Motor torque can be maximized with respect to machine
parameters using the Parametric Sweep feature in COMSOL
Multiphysics. A multipronged analysis of the motor by observing
the magnetic field distribution, electromagnetic torque, and iron
loss distribution allows engineers to optimize performance with
minimal weight and material costs.
Dr. Rahul Bhat is an applications engineer with COMSOL.
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Automotive Engineering - May 2021
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