Electric Drivetrain Innovation: Component to System Level Design
Feb 23rd 2022 - Feb 23rd 2022
Updated 14 January 2022
Please register at the bottom of this page
The UK’s EDISON Project is developing the first ferrite magnet motor with potential to be used in an automotive ePowertrain.
In this ‘X-motor’, the rotor features a ‘3D flux focusing’ layout for the magnets, where a ‘circumferentially magnetised’ assembly positioned in spokes interacts with two sets of ‘axially magnetised’ magnets in rings at each end. This arrangement delivers a resulting performance matching that of a conventional IPM.
This seminar will report the findings of the project, looking at materials, topologies, and machine modelling, optimisation, construction and testing.
The seminar will be a hybrid event with both in-person and online parts, although the event may be run wholly virtually if Covid restrictions change:
- The in-person part will be held at Jaguar Land Rover, Castle Bromwich, UK.
- The online part will include the presentations and its own networking opportunities. We will also be trialling cross-over activities between in-person and virtual delegates.
The in-person event will be held at Jaguar Land Rover, Castle Bromwich, UK. More details will be added when we have them.
VIRTUAL EVENT PLATFORM
The virtual part of the event will be hosted on Zoom. As well as the talks presented, you can also:
- visit and talk with exhibitors in the Breakout rooms
- Ask questions of speakers and send comments during the whole event via Chat
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Dassault Systemes UK
University of Sheffield
Jaguar Land Rover
Material Characterisation for a Ferrite Magnet Electrical Machine
by Daniel Brunt of NPL
Comparison of Ferrite and Rare Earth Machine Topologies
by Khoa Hoang, Giorgio Valente of University of Sheffield, Hexagon Applied Solutions
Building and Modal Testing a Prototype Radial Flux Machine
by TBC of Hexagon System Dynamics
High Performance Ferrite Machine Parameter Identification from Test
by Khoa Hoang of University of Sheffield
Electromechanical Effects Of Eccentricity in a Geared EDU
by Chris Riley of Dassault Systemes UK
One of the major goals of the Edison project was to develop software tools that allowed accurate system simulation of a complete electric drive unit (EDU). A typical EDU consists of an electric motor, bearings, shafts, gears, electronics and casing. Due to their interaction, all of these may be subject to vibration leading to excessive noise – although the individual components operate quietly in isolation. Two independent simulation software packages, SIMULIA Opera for electromagnetic modelling of the motor and Romax Evolve for mechanical simulation of the system, were coupled to achieve the software tools needed for accurate NVH (noise, vibration and harshness) simulation. This presentation describes the procedures developed by the Opera and Evolve teams to give a sufficient level of accuracy and highlights areas where numerical noise in the simulation can lead to spurious, non-physical mechanical response if not treated carefully.
A further aim of the project was to use these simulation tools to identify the types of mechanical deformation to the motor, resulting from its interaction with the drive system, that lead to excessive NVH. Among the sensitivity studies performed, using an 8-pole, internal permanent magnet (IPM) motor in the EDU, were:
• stator ovalling
• tooth rocking
• rotor tilt
• rotor eccentricity
• tooth rocking
• forward rotor whirl
The presentation will discuss some of the results, in particular showing how the stator tooth forces are affected and what the resulting mechanical response is. The partners will also discuss how they “closed the loop”, so that deflections calculated in Evolve could be applied to the Opera model for the dynamic tooth rocking simulation.
Reduced Order Modelling for Electromagnetic Analysis of Electrical Machines
by Bilquis Mohamodhosen of Dassault Systemes UK
During motor conception, it is usually desired to generate results over the entire operating range of the machine. This can be very time consuming when running Finite Element (FE) models, and hence a faster way would be more practical. Reduced Order Modelling (ROM) is an efficient way to capture the behavior of the model over the operating range into a meta/analytical model at the expense of slightly less accurate results.
A methodology to generate a sufficiently accurate reduced order model has been developed throughout the EDISON project using two coupled SIMULIA tools: Opera and Isight. Opera was used to run the FE models, and Isight to create a Design of Experiment for the entire operating range. The intention was to output the radial and tangential forces in the stator teeth of the machine for different values of direct and quadrature currents (Id & Iq). An analytical model as a function of these inputs and outputs was then derived, so that forces could be easily calculated at each operating point.
A Co-Simulation Method for True System Optimisation of EDUs
by Kyle Grubb of GRM Consulting
Since 2008, GRM Consulting Ltd have worked with major OEMs to develop innovative new methods and processes which enable multiple attributes of performance to be optimised for simultaneously.
During this time, we have investigated the development of gearbox, motor and EDU casings and mounting points to deliver noise, stiffness and strength requirements, allowing an EDU and its gear train to achieve the best performance possible.
The EDISON project brought together Romax Technology, Jaguar Land Rover, Dassault Systemes, The National Physical Laboratory and The University of Sheffield with GRM to investigate the field of transmission optimisation but with a particular focus on electric vehicle applications.
The primary aim of this project was to reduce vehicle emissions by developing novel ferrite motor technology for a passenger vehicle application. GRM and Romax supported engineers by enabling the electromagnetic, structural strength and dynamic transmission performance of a particular concept to be optimised for concurrently.
This presentation will provide an insight into the methods we’ve employed and provide case studies and potential valuable learnings for attendees that GRM have developed in partnership with major OEMs—such as Jaguar Land Rover, Tata Motors and a multitude of academic institutions throughout the UK.
GRM shall explore how the EDISON project has delivered the integration and optimisation of multiple physics for electric drive design problems. Furthermore, the application of the ‘EDISON’ coupled optimisation method to a wind turbine casing to ensure planetary gear misalignment will be presented.
eNVH of an Integrated Geared-Drivetrain System from Test and Simulation
by TBC of Hexagon System Dynamics
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