Search Results (14)

Electric vehicle (EV) proliferation is accelerating, characterized by the rising quantity of electric automobiles on global roadways. The electric machine is a crucial component of an EV, and the heat generated within the motor requires consideration as it impacts performance and longevity. A prevalent form of machine in EV is the in-wheel motor (IWM), which is notable for its compact size. However, it presents more significant cooling challenges. This research offers a new cooling method to cool the IWM. The system consists of wafters mounted on the housing of the IWM. Testing was conducted to determine the effect of wafters on the thermal properties and performance of IWMs. The machine used in this research is a brushless direct current (BLDC) motor featuring an outer rotor configuration and a peak power output of 1.5 kW. Testing was carried out experimentally and by simulation, and the simulation used Ansys Motor-CAD software. The research results show that applying wafers to IWM reduces the temperature of IWM components by up to 13.1%. IWM with wafters results in a torque increase of 0.14%, a power increase of 0.64%, and an efficiency improvement of 0.6% compared to IWM without wafters. Full article

This research proposes a novel cooling system to minimize the external rotor type of electric motor temperature by installing fan blades (wafters) on the inner housing of the electric motor. Fan blades (wafters) are made by printing using 3D printer technology and using polylactic acid (PLA) as the material. Wafters are then installed on an in-wheel motor with a power of 1500 W, having 48 poles and 52 slots. The study included thermal simulation and experimental techniques to ascertain how fan blades (wafters) affected the electric motor’s thermal properties. The motor rotated at 500 rpm during the experimental test with no load condition. The temperature of the electric motor is known using an infrared thermal imager. Using Ansys Motor-CAD 15.1 software, thermal modeling employs the lumped circuit model approach. Thermal simulation results show almost the same results as the experimental test results. Applying wafters on the in-wheel motor housing significantly reduces the winding temperature by 3.047 °C or experiences a temperature reduction of 4.34%. Using wafters in the in-wheel motor housing also speeds up the stable state temperature of the electric motor by 9 min compared to in-wheel motors without wafters. Full article

The construction hoist drive system is a critical component of the construction hoist, and high speed and low vibration noise are essential development directions. In order to improve the NVH level of the construction hoist drive system, this paper carries out research and analysis of construction hoist drive system excitation, establishes the drive system rigid-flexible coupling dynamics model, and completes the establishment of the vibration and noise model of the drive system, simulation analysis, and optimization work. Ansys Motor CAD 2020 was used to establish the parametric model of the asynchronous motor and it was combined with the virtual work method to calculate Maxwell’s electromagnetic force to arrive at the radial electromagnetic force as the main cause of electromagnetic noise. For the mechanical excitation generated by the gearbox, the time-varying stiffness excitation, mesh shock excitation, and transmission error excitation are considered, and the transmission error of helical gears under different working conditions is calculated by combining it with Romax software 2020. The rigid-flexible coupling model of the construction hoist drive system is established. The load distribution analysis of the unit length of the tooth surface is completed for the first- and third-stage helical gears under different working conditions. The primary source of the drive system excitation is the tooth surface bias load. Based on the dynamic response analysis theory of the vibration superposition method, the maximum vibration speed of the drive system was analyzed by Romax. The maximum noise value of 78.8 dB was calculated from the acoustic power simulation of the drive system using Actran acoustic software 2022 in combination with acoustic theory, and the magnetic density amplitude of the stator teeth of the asynchronous motor was optimized based on the microscopic shaping design of the helical gear by Romax. The vibration and noise simulation of the optimized drive system shows that the vibration value is reduced to 0.75 mm/s, and the maximum noise is reduced to 70.2 dB, which is 10.9% lower than before the optimization. The overall NVH level has been improved. The optimization method to reduce the vibration noise of the drive system is explored, which can be used for vibration noise prediction and control during the development of the construction hoist drive system. Full article

The driving motor is one of the most crucial components of an electric vehicle (EV). The most commonly used type of motor in EVs is the induction motor. These motors generate heat during operation due to the flow of electrical current through the motor’s coils, as well as friction and other factors. For long-run and high efficiency of the motor, cooling becomes more important. This article utilized ANSYS Motor-CAD to map the temperature signature of an induction motor and investigated the thermal efficiency of using nanofluids as a cooling medium. The thermal conductivity of nanofluids has been found to be superior to that of more conventional cooling fluids such as air and water. This research explores the effect of using Al₂O₃, ZnO, and CuO concentrations in nanofluids (water as a base fluid) on the thermal efficacy and performance of motor. According to the findings, using nanofluids may considerably increase the efficiency of the motor, thereby lowering temperature rise and boosting system effectiveness. Based on the simulation analysis using ANSYS Motor-CAD, the results demonstrate that the utilization of CuO nanofluid as a cooling medium in the induction motor led to a reduction of 10% in the temperature of the motor housing. The maximum reduction in the temperature was found up to 10% when nanofluids were used, which confirms CuO as an excellent option of nanofluids for use as motor cooling and other applications where effective heat transmission is crucial. Full article

This article presents the design of a drive system for robots and manipulators, which is based on the finite element method of an induction motor. The design process involves constructing a computer-aided design (CAD) model of the induction motor, which enables the generation of design documentation and control programs for computer numerical control (CNC) tools for manufacturing motor parts or conducting further research. A CAD model is developed for performing a finite element analysis of the motor in the SolidWorks software based on the popular AIR63V2 motor. The design of the motor’s housing, rotor, and stator is developed. Additionally, the electrical parameters of the motor are calculated using Ansys Electronic Suite—Maxwell RMxprt, utilizing the classical analytical theory of electrical machines and the equivalent magnetic circuit method. This takes into account such effects as the non-linearity of electrical steel, the non-sinusoidality of the magnetic flux in the gap, and the displacement of electric current in massive conductors. A complete model of an induction motor for research has been created, enabling the study of dependencies of speed and electromagnetic torque of an induction motor. The natural frequency of the rotor is calculated, which ranges from 922 Hz to 1015 Hz. The obtained values of calculations of natural oscillations of the CAD model of the motor can be used for motor diagnostics. Furthermore, the created project in the Ansys software can be utilized to design an induction motor with its own characteristics, optimized for specific tasks. Full article

This paper deals with the simulation of a permanent magnet synchronous machine (PMSM) to be developed for driving a scroll compressor of a vehicle air conditioning system. The simulations were needed for the verification of the pre-sizing and for the electromagnetic behavior analysis of the PMSM. These were performed by using the ANSYS Motor-CAD software. All the obtained results emphasized that the pre-sizing of the PMSM was performed correctly, and the designed electrical machine can fulfill all the prescribed requirements. To highlight the superiority of the chosen surface-mounted PMSM topology, a comparative study was performed for four PMSMs having the same stator but different rotor topologies having the same quantity of permanent magnets. The study revealed that the PMSM with permanent magnets on its rotor surface is the best-fitting variant for the foreseen application. By intensively using the ANSYS Motor-CAD software, the authors appreciated that this product is a very useful tool in the hands of the designers not only in evaluating the machine’s computed geometry (by checking its correctness and feasibility), but also in its in-depth electromagnetic analysis and in calculating its parameters of interest. Full article

The article presents the analysis of operational parameters and thermal analysis of the wheel hub motor during operation in the car drive. The authors proposed an analysis of the operation of the wheel hub motor mounted in a hybrid car, during Artemis driving cycles and while driving on the road with different slopes. The simulations were carried out in the Ansys Motor-CAD program. The calculations are based on coupled models of the electromagnetic circuit and thermal models of the motor. The conducted research is a proposal of an approach to the design of electric vehicle propulsion motors, which allows us to consider problems related to predicting at the motor design stage what are its possibilities and what risks during operation in a real drive. The analysis also includes the impact of the applied motor control strategy and the variation of the supply voltage. These are aspects that are extremely important in wheel hub motors, as they are weight-optimized motors with a limited volume and a relatively high power and torque density. Full article

In the electromagnetic design process of the outer rotor of a low-speed permanent magnet motor (LSPMM), due to the different heat dissipation conditions of the stator core and the stator winding, the selection of different magnetic loads and stator current densities will produce different temperature distributions even under the same efficiency. In the existing literature, the effects of magnetic load and current density on temperature distribution are rarely studied, which makes it difficult for designers to select optimal electromagnetic parameters to achieve better temperature performance. Therefore, in this paper, the comparison of temperature characteristics considering magnetic load and current density is conducted based on an outer rotor LSPMM. Firstly, the structure and parameters of an initial scheme of a 200 kW 56 rpm motor is determined, and the electromagnetic and temperature characteristics of the initial scheme are obtained through two-dimensional finite element analysis (2D-FEA) using Ansys Maxwell and Motor-CAD software. Secondly, by comparing the temperature and loss characteristics under different magnetic loads and different current densities, the effect of magnetic load on temperature and the effect of current density on temperature are obtained. Furthermore, four different schemes are proposed, and the loss and temperature characteristics of the four schemes under rated load are also compared to obtain the comprehensive effects of magnetic load and current density on temperature. Next, a final scheme is determined based on the above analysis, and the temperature characteristics of the final scheme and the initial scheme are compared to verify the validity of the conclusions. Finally, a prototype is built and tested to verify the feasibility of the conclusions. For LSPMM design, the results and several measurements provided in this paper can help researchers to choose a better optimization scheme to achieve good temperature performance. Full article

For high-speed permanent magnet machines (HSPMMs), many design schemes of rotor length–diameter ratios can satisfy the constraints of multiple physical fields during the motor design period. The rotor length–diameter ratio greatly impacts the comprehensive performances of multiple physical fields. However, these analyses are missing in the existing literature. Therefore, this paper focuses on the influence of the rotor length–diameter ratio on comprehensive performances. Firstly, finite element models (FEM) of multiple physical fields are built by ANSYS Workbench platform and Motor-CAD software. Then, the comprehensive performances of multiple physical fields are comparatively analyzed. Finally, the designed HSPMM is implemented, based on one prototype of 60 kW, 30,000 rpm to verify the results of comparative analysis. Based on the comparative analysis above, the influent laws of rotor length–diameter ratios on comprehensive performances of multiple physical fields are discussed and summarized, which can be used as a reference for the rotor structural design of HSPMMs. Full article

Recent research reveals that multi-phase motors in electric propulsion systems are highly recommended due to their improved reliability and efficiency over traditional three phase motors. This research presented a comparison of optimal model design of a six phase squirrel cage induction motor (IM) for electric propulsion by using Genetic Algorithm (GA) and Particle Swarm Optimization (PSO). A six phase squirrel cage induction motor is designed and simulated by ANSYS Motor-CAD. In order to find the best fit method, simulation results are compared and applied to the motors for electric propulsion, considering the influence of design upon the motor performance. The six-phase squirrel cage induction motor is more energy efficient, reliable and cost effective for the electric propulsion compared to the conventional three phase motor. In this study, first the initial parameters of the six phase squirrel cage induction motor have been determined and then these parameters have been compared with optimized values by Genetic Algorithm (GA) and PSO optimization. The motor designed is optimized using efficiency and power losses as the fitness function. The six phase squirrel cage induction motor is designed using ANSYS Motor-CAD and the simulation results were also presented along with two-dimensional and three-dimensional geometry. The result shows that the weight and power loss are reduced to 161 kg and 0.9359 Kw respectively, while the efficiency and power factor are increased to 0.95 and 0.87 respectively when PSO is used. This shows that the result is promising. Full article

A chassis is one of the vital parts of a heavy motor vehicle, which provides rigidity to the vehicle and improves structural stability and rigidity for accurate handling. The design and material of a chassis structure significantly affects its strength and weight. Optimization techniques can be used in systematic design improvement of chassis to meet industry requirements. The current research is intended to optimize the design of chassis using the Box–Behnken design scheme and the material tested is P100/6061 Al and Al GA 7-230 MMC. Different design points were generated using the design of the experiments. Equivalent stress, deformation and mass were evaluated for each design point. The variable selected for optimization using the Box–Behnken scheme was cross member width. The CAD modelling and FE simulation of the heavy motor vehicle chassis were conducted using ANSYS software. From the optimization conducted on the chassis design, response surface plots of equivalent stress, deformation and mass were generated, which enabled to determine the range of dimensions for which these parameters are maximum or minimum. The sensitivity plots of different variables were generated, which has shown that cross member 2’s width has a maximum effect on equivalent stress and cross member 3’s width has a minimum effect on equivalent stress, whereas for total deformation, cross member 3 shows the maximum sensitivity percentage, which signifies that cross member 3 has the maximum effect on total deformation, and vice versa. The use of the aluminium metal matrix composites P100/6061 Al and Al GA 7-230 MMC aided to reduce the weight of the chassis by 68% and 70%, respectively, without much reduction in the strength of the chassis. Full article

In order to improve the quality of the laser and shorten the optical path of the fast steering mirror (FSM) laser compensation system, this paper proposes a four-degrees-of-freedom (4-DOF) voice coil motor (VCM) with the function of reducing laser geometrical fluctuations. The feature of this paper is the combination of a DC brushed spindle motor and the proposed 4-DOF VCM. A diffuser is installed on the shaft of the DC brushed motor for suppressing the laser speckle. The proposed 4-DOF VCM is combined with a laboratory-designed mirror set, controlling the laser direction to compensate for laser fluctuations. The proposed actuator was designed and verified by using the commercial CAD software SolidWorks and finite element analysis (FEA) software ANSYS. A mathematical model was built to simulate the dynamic response of the proposed 4-DOF VCM in MATLAB Simulink. Full article

This work aimed to develop a parameterized, two-dimensional field model of a switched reluctance motor (SRM). The main task of the developed model was to calculate the value of the electromagnetic torque for various positions of the rotor. Based on these calculations, the characteristics of the electromagnetic torque were determined depending on the position of the rotor angle φ for the current function I (T = f (φ, I)). Using the model, it was possible to additionally observe the phenomena occurring in the motor winding, e.g., distributions, isolines of magnetic potential, induction, and to calculate the values of the temperature. The parameterized structural elements that made up the entire model can be freely changed and, thus, the results for various structures can be obtained. Thanks to this, it was possible to evaluate and compare motor of different designs. To validate the model, measurements were conducted on real-scale reluctance motors, and families of electromagnetic torque characteristics were obtained for various design cases. The results received from the tested motors were juxtaposed with simulation results procured via the model. Based on this comparison, it was possible to determine the accuracy of the model’s operation. Full article

The primary supporting structure of an automobile and its other vital systems is the chassis. The chassis structure is required to bear high shock, stresses, and vibration, and therefore it should possess adequate strength. The objective of current research is to analyze a heavy motor vehicle chassis using numerical and experimental methods. The CAD design and FE analysis is conducted using the ANSYS software. The design of the chassis is then optimized using Taguchi design of Experiments (DOE); the optimization techniques used are the central composite design (CCD) scheme and optimal space filling (OSF) design. Thereafter, sensitivity plots and response surface plots are generated. These plots allow us to determine the critical range of optimized chassis geometry values. The optimization results obtained from the CCD design scheme show that cross member 1 has a higher effect on the equivalent stresses as compared to cross members 2 and 3. The chassis mass reduction obtained from the CCD scheme is approximately 5.3%. The optimization results obtained from the OSF scheme shows that cross member 2 has a higher effect on equivalent stress as compared to cross members 1 and 3. The chassis mass reduction obtained from optimal space filling design scheme is approximately 4.35%. Full article